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IN-1
MODELS
INTRODUCTION EX135W

EXCAVATOR

WORKSHOP MANUAL

F5053

IMPORTANT: The information contained in this manual are valid at printing time. As the Manufacturer
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continuously improves his products, some information may not be updated. In case of discrepancies, apply
to Sales and Service Department.

FIAT - HITACHI EXCAVATORS S.p.A. - ENGINEERING - PRINT 604.06.991

Edition September 2000 - Printed in Italy
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IN-3

INTRODUCTION EX135W

TO THE READER

• This manual has been written for a skilled - For any question or comment, or in case you
technician, in order to give him the information notice a mistake in this manual content,
necessary to repair this machine. please contact:

- Read this manual carefully for correct FIAT-HITACHI EXCAVATORS S.p.A.

information about repair procedures. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also

to the following:

- Operation and maintenance instruction

manual
- Spare parts catalog

DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL

• The complete repair manual consists of two • "Excavator" and "Engine" Workshop Manuals
volumes: contain the technical information necessary for
machine/engine service and repair, service
- EX135W - Workshop Manual "Excavator" equipment, information on maintenance
standards, remove and install procedures,
- EX135W-EX165W - Workshop Manual disassembly and assembly procedures.
"Engine"
• The complete Workshop Manual for the
excavator model EX135W consists of the
following volumes identified by print number as
shown herebelow:
21599 60406991

VOLUME MACHINE TYPE PRINT No.

Workshop Manuals - "Excavator" EX135W 604.06.991
Workshop Manuals - "Engine" EX135W-EX165W 604.06.971
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IN-4

INTRODUCTION EX135W

AVOID ACCIDENTS

Most accidents, whether they occur in industry, on the farm, at home or

on the highway, are caused by the failure of some individuals to follow
simple and fundamental safety rules or precautions. For this reason
MOST ACCIDENTS CAN BE PREVENTED by recognising the real
cause and doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type
of equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient
operation.
Carefully read indications, cautions and safety warning quoted in the
“SAFETY RULES” section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many
thousand serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.

ATTENTION

On machines having hydraulically, mechanically and/or cable

controlled equipment (such as showels, loaders, dozers, scrapers
etc.) be certain the equipment is lowered to the ground before
servicing, adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised to
gain access to certain items, be sure the equipment is suitably
supported by means other than the hydraulic lift cylinders, cable
and/or mechanical device used for controlling the equipment.

COPYRIGHT BY FIAT-HITACHI EXCAVATORS S.p.A.

Product Support - Documentation Centre
Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY
21599 60406991

All rights reserved. Reproduction of text and illustrations in whole or in part,

is strictly prohibited.
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INDEX EX135W - 1 - 1

SECTION 1 HOW TO USE

INDEX

Group 1 - SECTIONS AND GROUPS INDEXES ......................................................... HU1-1-1

Group 2 - INTRODUCTION.......................................................................................... HU1-2-1

2.1 Introduction
2.2 Manual handling
2.3 Symbols and indications

Group 3 - FEATURES OF THE MANUAL ................................................................... HU1-3-1

3.1 Manual composition

3.2 Brief information for manual consultation
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HU1-1-1

SECTIONS AND GROUPS INDEXES EX135W

1. SECTIONS AND GROUPS INDEXES PAGES

SECTION 1 - HOW TO USE

Group 1 - SECTIONS AND GROUPS INDEXES ........................................................... HU1-1
Group 2 - INTRODUCTION ............................................................................................ HU1-2
Group 3 - FEATURES OF THE MANUAL ...................................................................... HU1-3

SECTION 2 - SAFETY RULES

Group 1 - GENERAL INFORMATION ............................................................................ SR2-1
Group 2 - SAFETY RULES ............................................................................................ SR2-2
Group 3 - SAFETY DECALS .......................................................................................... SR2-3

SECTION 3 - SPECIFICATION
Group 1 - GENERALITY ................................................................................................. SP3-1
Group 2 - TECHNICAL SPECIFICATIONS .................................................................... SP3-2
Group 3 - LUBRICANTS AND SPECIFICATIONS ......................................................... SP3-3

SECTION 4 - SUPERSTRUCTURE
Group 1 - SUPERSTRUCTURE ..................................................................................... SS4-1
Group 2 - HYDRAULIC PUMPS ................................................................................... HYP4-2
Group 3 - CONTROL VALVE ......................................................................................... CV4-3
Group 4 - SWING DEVICE .......................................................................................... SRD4-4
Group 5 - PILOT VALVES .............................................................................................. PV4-5
Group 6 - CENTER JOINT ..............................................................................................CJ4-6
Group 7 - STEERING VALVE ........................................................................................ SV4-7
Group 8 - BRAKE PEDAL VALVE ................................................................................ BRV4-8
Group 9 - ACCUMULATORS ...................................................................................... ACC4-9
Group 10 - SOLENOID VALVES ............................................................................... SOV4-10
Group 11 - PRIORITY VALVE ....................................................................................PRV4-11

SECTION 5 - UNDERCARRIAGE
Group 1 - UNDERCARRIAGE ........................................................................................ UC5-1
Group 2 - TRAVEL HYDRAULIC MOTOR .................................................................. HYM5-2
Group 3 - TRANSMISSION ............................................................................................ TM5-3
Group 4 - AXLES ............................................................................................................ AX5-4
Group 5 - TRANSMISSION SHAFT ............................................................................... TS5-5

SECTION 6 - FRONT-END ATTACHMENT

Group 1 - FRONT-END ATTACHMENT ......................................................................... FA6-1
Group 2 - HYDRAULIC CYLINDERS ............................................................................. CY6-2
Group 3 - PINS AND BUSHINGS ................................................................................... FA6-3

SECTION 7 - HYDRAULIC SYSTEM

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Group 1 - GENERALITIES ............................................................................................. HS7-1

Group 2 - MAIN HYDRAULIC SYSTEM ......................................................................... HS7-2
Group 3 - PILOT/BRAKES SYSTEM .............................................................................. HS7-3
Group 4 - STEERING SYSTEM ..................................................................................... HS7-4
Group 5 - BRAKES SYSTEM ......................................................................................... HS7-5
Group 6 - OPERATION OF CIRCUITS .......................................................................... HS7-6
Group 7 - TRAVEL CIRCUIT .......................................................................................... HS7-7
Group 8 - HYDRAULIC SYSTEM DIAGRAM ................................................................. HS7-8
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HU1-1-2

SECTIONS AND GROUPS INDEXES EX135W

SECTION 8 - ELECTRICAL SYSTEM

Group 1 - SAFETY RULES ............................................................................................ ES8-1
Group 2 - SPECIFICATIONS AND DATA ...................................................................... ES8-2
Group 3 - LOCATION AND FUNCTIONS OF COMPONENTS ...................................... ES8-3
Group 4 - ARRANGEMENTS AND OPERATION .......................................................... ES8-4
Group 5 - ELECTRONIC CONTROL UNITS AND DIODES .......................................... ES8-5
Group 6 - ELECTRIC COMPONENTS ........................................................................... ES8-6
Group 7 - WIRE HARNESSES ....................................................................................... ES8-7

SECTION 9 - TROUBLESHOOTING
Group 1 - INTRODUCTION ............................................................................................ TS9-1
Group 2 - HYDRAULIC SYSTEM TROUBLESHOOTING .............................................. TS9-2
Group 3 - ELECTRICAL SYSTEM TROUBLESHOOTING ............................................ TS9-3

SECTION 10 - OPERATIONAL PERFORMANCE TEST

Group 1 - INTRODUCTION .......................................................................................... PT10-1
Group 2 - PERFORMANCE STANDARD ..................................................................... PT10-2
Group 3 - PREPARATION FOR PERFORMANCE TEST ............................................ PT10-3
Group 4 - EXCAVATOR PEFORMANCE TEST ........................................................... PT10-4
Group 5 - COMPONENTS PERFORMANCE TEST .................................................... PT10-5

SECTION 11 - APPENDIX
Group 1 - APPENDIX ................................................................................................. APP11-1
?

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HU1-2-1

INTRODUCTION EX135W

2. INTRODUCTION

2.1 INTRODUCTION

This service manual has been prepared in order to increase repair quality, providing to the technicians the
elements for a good knowledge of the product and showing the proper procedures to carry out the
maintenance operations. We recommend to thoroughly read the content and follow it when necessary.

It is a concise guide for a specific machine. It covers construction features, operation principle, troubleshooting,
disassembly and assembly of components and repair action.

Using this manual in systematic and rational way it is possible to reduce the repairing errors and delay that
could cause machine stop with a detriment of cost management.

The information quoted in this service manual are supplied also to be used for training aids. Therefore it is
advisable to be used in the training of new personnel that will be employed in the machine maintenance.

All the information, illustrations and specifications contained in this service manual are based on the latest
product information available at the time of publication.
FIAT-HITACHI reserves the right to makes changes at any time without notice to this service manual for
technical or trading reasons.
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2.2 MANUAL HANDLING

2.2.1 CHANGES AND SUPPLEMENTS

This service manual is carried out in loose-leaf and therefore can be easily kept up-to-date.
The personnel in charge is responsible for updating the manual and will insert the changes or supplements
that FIAT-HITACHI will issue to its service organisation.
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HU1-2-2

INTRODUCTION EX135W

2.3 SYMBOLS AND INDICATIONS

In this service manual, symbols and indications are used to draw the attention on important points for safety
and quality.

2.3.1 SAFETY

This safety symbol is used for important safety message. When you see this symbol, be alert to the
potential for personal injury. Strictly follow the recommended precautions.

2.3.2 INDICATIONS

Reading this service manual you can find indications as “IMPORTANT” or “Note” that have the following
meaning:

• IMPORTANT
Indicates a situation which, if not avoided, could caused damages to the machine.

• Note
Indicates supplementary technical information or know-how.
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HU1-3-1

FEATURES OF THE MANUAL EX13 5W

3. FEATURES OF THE MANUAL

3.1 MANUAL COMPOSITION

This service manual is divided into eleven Sections. The Section names and its contents are as below. To
fully use this service manual it is essential to understand how it is organised. Therefore, in order to speed up
the searching of wished subject, it is advisable to carefully read this chapter.

SECTION 1 - HOW TO USE

Begin to read first this Section to know the manual composition. This will help you for subject
searching.

SECTION 2 - SAFETY RULES

Indication on how to avoid dangerous situation during the use and maintenance are given in this
Section.
Furthermore safety decals and relate indications used on the machine are listed on this Section.

SECTION 3 - SPECIFICATION
This Section quotes the specification and data of the machine.

SECTION 4 - SUPERSTRUCTURE
This Section contains the information relate to operation principle of the systems, of the
assemblies and their components located on the machine upper frame. Furthermore the
assembly/disassembly procedures of main devices are quoted.
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FEATURES OF THE MANUAL EX135W

SECTION 5 - UNDERCARRIAGE
This Section contains the information relate to operation principle of the systems, of the
assemblies and their components located on the machine lower frame. Furthermore the
assembly/disassembly procedures of main devices are quoted (axles, transmission, travels
motor, etc.).

SECTION 6 - FRONT-END ATTACHMENT

This Section describes the front-end attachment and its components and maintenance rules with
related disassembly/assembly.

SECTION 7 - HYDRAULIC SYSTEM

This Section describes the operation of the machine from hydraulic point of view.

SECTION 8 - ELECTRICAL SYSTEM

This Section describes the electric system of the machine, the main electrical component and
the connection with the electrical users.

SECTION 9 - TROUBLESHOOTING
In this Section information is provided for troubleshooting to the hydraulic and electric systems
and the necessary instruction to use the support equipment (test harnesses and test device).

SECTION 10 - OPERATIONAL PERFORMANCE TEST

Performance data and the procedures to detect data are provided in this Section.
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SECTION 11 - APPENDIX
Performance data and the procedures to detect data are provided in this Section before the
? modification.
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FEATURES OF THE MANUAL EX13 5W

3.2 BRIEF INFORMATION FOR MANUAL CONSULTATION

The manual is divided into section, each of them quotes a specific portion of the machine or specific related
subject.

Some section (those related to main mechanical assembly) are divided into:
• O/P (Operation Principle)
• D/A (Disassembly/Assembly)

In the Operation Principle, the assemblies and their components are described with technical data.

In the disassembly and assembly the procedures are described to perform repair or overhaul, with special tool
required and technical data.

Each section is divided into group, and the group, in turn, in pages. Each page has a number, located in the
upper right corner. Each number contains the following information;

• example:

SR 3 - 2 - 1

Consecutive page number for each group.

▼

Group number.
▼ ▼ ▼

Section number.
Section or Group abbreviation.
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HU1-3-4

FEATURES OF THE MANUAL EX135W

NOTES:

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INDEX EX135W - 2 - 1

SECTION 2 SAFETY RULES

INDEX

Group 1 - GENERALITIES............................................................................................ SR2-1-1

1.1 Starting
1.2 Operating
1.3 Stopping
1.4 Maintenance

Group 2 - SAFETY RULES ........................................................................................... SR2-2-1

Group 3 - SAFETY DECALS ........................................................................................ SR2-3-1

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21599 60406991

SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction
Manual carefully before starting, operating,
maintaining, fuelling or servicing the machine.
Carefully read the explanation to each and all safety
signs in the special section of this Manual before
starting, operating, maintaining, fuelling or servicing
the machine.
Machine-mounted safety plates are colour coded
yellow with black borders when they refer to points
where special ATTENTION must be paid and failure
to observe them may cause a serious DANGER to the
integrity of machine operators. They are white with
red borders and black lettering when they refer to a
FORBIDDEN practice.
It is fundamental that all machine operators know very
well the meaning of each safety plate as this
considerably decreases operating hazards and
accidents.
Do not allow unauthorised personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses , reflector vests, respirators
every time the job requires it. Ask your employer
about safety regulations in force and protective
equipment.
Always keep the operator’s compartment, step plates,
grab-rails and handles clean and clear of foreign
objects, oil, grease, mud or snow to minimise the
danger of slipping or stumbling. Remove mud or
grease from your shoes before operating the
machine.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Never operate the machine or its attachments from
any position other than sitting in the driver’s seat.
Keep head, body, limbs, hands and feet inside the
operator’s compartment at all times to reduce
exposure to external hazards.
Be careful of possible slippery conditions of the steps
and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber.
Do not leave the machine until it has come to a
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complete stop.
Always check height, width and weight limitations
which may be encountered in the working site and
ensure the machine does not exceed them.
Assess exact paths of gas ducts, water mains,
telephone lines, sewers, overhead and underground
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SR2-1-1
electric lines and all other possible obstacles.
Such paths should be opportunely defined by
competent Authorities. If necessary, require that the
service is interrupted or said installations are moved
prior to starting the work.
You must know the working capacity of the machine.
Define the rear upperstructure swing area and provide
for opportune barriers to prevent access into it.
Never exceed machine lifting capacity.
Remain within the limits shown in the loading capacity
chart located on the machine.
STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly
removed. Before starting machine, check that steering
and attachment controls are in the neutral position
and the safety lever is in the LOCK position.
Immediately report any malfunction of parts or
systems to the maintenance managers for proper
action.
Prior to starting the engine, check, adjust and lock the
driver’s seat for maximum riding comfort and control
accessibility. Prior to operating the machine and/or its
attachments, check that bystanders are outside the
machine operating range. Sound the horn.
Obey all hand signals, safety indications and signs.
Due to the presence of flammable fluids, never check
fuel level, refuel, charge the batteries or use the
starting fluid in the presence of smoking materials,
open flames or sparks.
Ensure that nobody is within the excavator operating
area before starting the machine, swinging the upper
structure or moving in any direction.
Adjust all rear-view mirrors for maximum visibility of
the area behind the machine.
Ensure that engine speed is appropriate to the job to
be carried out.
If any hydraulic control or system exhibits erratic
performance or responds abnormally, have the
machine checked for air in the system.
Air in these circuits may cause incorrect movements
with consequent accident hazard. Refer to the
Operation and Maintenance Instruction Manual about
corrective action to be taken.
OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to remove
harmful exhaust gases which concentrate in the air.
Keep the operator’s compartment free of foreign
objects, especially if not firmly secured. Never use the
machine to transport objects, unless proper securing

SAFETY PRECAUTIONS
points are provided.
Do not carry riders on the machine.
Study and familiarise with escape routes alternative to
normal exit routes.
For your personal safety, do not climb on or off the
machine while it is in motion.
Make sure that bystanders are clear of the machine
operating range before starting the engine and
operating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.
When backing, always look to where the machine is
to be moved. Be alert of the position of bystanders.
Should someone enter the work area, stop the
machine.
Maintain a safe distance from other machines or
obstacles to ensure required visibility conditions.
Always give way to loaded machines.
Maintain a clear vision of the surroundings of the
travel or work area at all times.
Keep cab windows clean and repaired.
When pulling loads or towing through a cable or
chain, do not start suddenly at full throttle. Take-up
slack carefully.
Avoid kinking or twisting chains or cables.
Carefully inspect cables or chains for flaws or
problems before proceeding.
Do not pull through a kinked chain or cable as the
high anomalous stresses existing in this condition
may induce failures in the kinked portion.
Always wear heavy gloves when handling chains or
cables.
Chains and cables should be securely anchored using
suitable hooks. Anchor points should be strong
enough to withstand the expected load.
Keep anyone clear of anchor points and cables or
chains. Do not pull or tow unless the operator’s
compartments of the machines involved are
properly protected against possible backlash in
case of cable or chain failure or detachment.
Be alert of soft ground conditions close to newly
constructed walls. The fill material and machine
weight may cause the wall to collapse under the
machine.
In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
proper action. Do not operate the machine until this
condition is corrected.
Regularly check all exhaust system components, as
exhaust fumes are toxic for the operator.
Operators must know the performance of the
machine they are driving.
When working on slopes or near sudden level drops
in the terrain, pay attention not to lose adherence and
avoid loose soft ground since overturn or loss of
machine control could result.
If noise level is high and exceeds 90 dB(A) over 8
hours at the operator’s ear, wear approved ear
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SR2-1-2
protection in compliance with local regulations.
Do not operate the machine if you are extremely tired
or feel ill.
Be especially careful towards the end of the working
shift.
Where removable counterweights are provided, do
not operate the machine if they have been removed.
When operating the machine, keep in mind height
limits of overhead doors, arches, overhead cables
and lines as well as width limits of corridors, roads
and narrow passages. Also, get to know load limits of
the ground and paving type of the ramps you are to
work on.
Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain,
ditches, crowns, ridge trenches, diggings in traffic
areas, crowded parking lots, crowded service areas,
fenced zones. In such conditions, proceed with
extreme care.
Whenever possible, avoid crossing over obstacles
such as very rough terrain, rocks, logs, steps, ditches,
railroad tracks. When obstructions must be crossed,
do so with extreme care and at a square angle, if
possible. Slow down. Ease up to the break-over point,
pass the balance point slowly and ease down the
other side also using the attachment, if necessary.
To overcome deep trenches or sinking ground, place
the machine perpendicular to the obstacle, drastically
reduce ground speed and start crossing using also
the attachment if necessary, only after assessing that
ground conditions allow the traverse safely and
without risks.
The gradient you may attempt to overcome is limited
by factors such as ground conditions, load being
handled, machine type and speed, and visibility.
There is no substitute for good judgement and
experience when working on slopes.
Avoid operating the attachment too close to an
overhang or high wall, either above or below the
machine. Beware of caving edges, falling objects and
landslides. Remember that such hazards are likely to
be concealed by bushes, undergrowth and such.
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
that discontinue adherence or traction with the
ground, especially near slopes or drop-offs.
Be alert to avoid changes in adherence conditions
that could cause loss of control. Work with extreme
care on ice or frozen ground and on stepped slopes
or near drop-offs.
The word “bulldozing” generally refers to work in
virgin rough terrain, characterised by the presence of
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all the perils and risks listed above. We emphasise
the danger represented in these conditions by large
tree limbs (possibly falling on the machine) and large
roots (which may act as a leverage under the
machine when up-rooted and cause the unit to
overturn).

SAFETY PRECAUTIONS
Position the machine dependent upon the loading
and unloading areas in order to swing leftwards to
load to obtain best visibility.
Never use the bucket or attachment as a man lift
or carry riders.
Never use the machine as a work platform or
scaffolding. The machine must not be improperly
used for works not consistent with its features (such
as pushing railway cars, trucks or other machines).
Always pay attention to people within the machine
operating range.
Never move or stop the bucket, other loads or the
attachment above ground personnel or truck cabs.
Ensure the truck driver is in a safe place before
loading the truck.
Load trucks from side or rear.
Use only the type of bucket recommended
considering machine type, materials to be handled,
material piling up and loading characteristics, ground
type and other typical conditions of the work to be
performed.
When travelling with a loaded bucket, keep it as
rolled-back as possible. Keep boom and arm as low
as possible.
Ground speed should be adequate to the load and
ground conditions.
The load must always be properly arranged in the
bucket; move with extreme care when transporting
oversize loads.
Do not lift and move the bucket overhead where
persons are standing or working, nor downhill when
working on a slope as this would decrease machine
stability. Load the bucket from the uphill side.
Loads to be raised using the machine should be
exclusively hooked to the hitch specially provided.
The excavator is no lifting and transportation means,
therefore it should not be used to position loads
accurately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:
– The machine should necessarily be equipped with
the special option supplied by FIAT-HITACHI.
Follow also safety rules for the excavator used as
lifting means.
– Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
– Nobody should be allowed to remain under the
raised load or within the excavator operating range
for any reason whatever.
Never exceed specified loading capacity. Incorrect
fastening of slings or chains may cause boom/arm
failure or failure of the lifting means with consequent
bodily injuries and even death.
Always ensure that slings and chains used for lifting
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are adequate to the load and in good condition.
All loading capacities are referred to the machine
on a level surface and should be disregarded
when working on a slope.
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa. If machine starts slipping
sideways when on a slope, lower the bucket and
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thrust bucket teeth into the ground.
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
Do not move full bucket or a load from uphill downhill
as this would reduce machine stability. Do not work
with the bucket turned to the uphill side.
Do not work with the bucket turned uphill as
counterweights protruding downhill would reduce
machine stability on the slope and increase risk of
overturning.
We recommend to work on slopes with the bucket
downhill, after checking machine stability with the
bucket empty and attachment retracted, by slowly
swinging the upper structure by 360°.
Position the carriage at a right angle relative to
slopes, hanging walls, etc. to exit the working area
easily.
Be aware when the upperstructure is turned by 180°,
steering and travel controls are reversed.
Properly judge ground conditions with particular
attention to consistency of the area you are going to
work on.
Keep the machine sufficiently far from the ditch edge.
Never dig under the machine.
Should it be necessary to dig under the machine,
always ensure that digging walls are opportunely
propped up against landslide to prevent the machine
from falling into the trench.
Do not swing the upperstructure, raise the load or
brake abruptly if not required. This may cause
accidents.
Prior to beginning the work near gas distribution
mains or other public utilities:
- Contact the company owner of the gas mains or its
nearest branch before starting the work. Look up
the number in the telephone directory.
- Define together which precautions should be taken
to guarantee work safety.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- When working near gas mains or other public
utilities installations, appoint a person in charge of
signalling duties. This person will have the
responsibility of observing the machine, any part of
it and/or the load approaching the gas mains from a
standpoint more favourable than the Operator’s.
This signal man (flag-man) must be in direct
communication with the Operator and the Operator
must pay undivided attention to the signals
supplied.
- The gas distributing Company, if previously advised
and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
entity having rent or leased the machine or being
responsible at the time by contract or by law, are
liable for the adoption of the necessary precautions.
Working near electric lines can be very dangerous,
therefore some special precautions must be
observed.
Within this Manual, “work near electric lines” means

SAFETY PRECAUTIONS
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass
minimum safety distance. Ensure that local or
national safety regulations concerning work near
electric lines are observed.
Prior to beginning the work near electric lines:
- Contact the Company owner of the electric lines or
its nearest branch before starting the work.
Look up the in the telephone directory.
- Define together with the Company representative
which precautions should be taken to guarantee
work safety.
- All electric lines should be considered as operative
live lines even though it might be well known that
the line in question is out of work and visibly
connected to the ground.
- The Electric Power Company, if previously advised
and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
entity having rent or leased the machine or being
responsible at the time by contract or by law, are
liable for the adoption of the necessary precautions.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- Warn all ground personnel to keep clear of the
machine and/or load at all times. If the load has to
be guided down for laying, consult the Electric
Power Company to know which precautions should
be taken.
- Appoint a person in charge of signalling duties.
This person will have the responsibility of observing
the machine, any part of it and/or the load
approaching the electric lines from a standpoint
more favourable than the Operator’s. This signal
man (flag-man) must be in direct communication
with the Operator and the Operator must pay
undivided attention to the signals supplied.
When working in or near pits, in ditches or very high
walls, check that the walls are sufficiently propped up
to avoid cave-in hazards.
Pay the utmost attention when working near overhang
walls or where landslides may take place. Make sure
that the support surface is strong enough to prevent
landslides.
When digging, there is the risk of cave-ins and
landslides.
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is
required to prevent possible cave-ins or landslides
when:
- digging near previous trenches filled with material,
- digging in bad ground conditions,
- digging trenches subject to vibration from railroads,
working machines or highway traffic.
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STOPPING
When the machine is to be stopped for whatever
reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
position to guarantee risk-free start-up.
Never leave the machine unattended with the engine
running.
Prior to leaving the driver’s seat, and after making
sure that all people are clear of the machine, slowly
lower the attachment until resting it safely to the
ground. Retract possible auxiliary tools to the closed
safety position.
Check that all controls are in the neutral position.
Move engine controls to the shut-down position.
Switch off the key-start switch. Consult the Operation
and Maintenance Instruction Manual.
Park the machine in a non-operating and no-traffic
area. Park on firm level ground. If this is not possible,
position the machine at a right angle to the slope,
making sure there is no danger of uncontrolled
sliding.
If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and other signals as
required to adequately warn the oncoming drivers.
Always switch off the key-start switch before cleaning,
repairing or servicing, or parking the machine to
prevent accidental unauthorised start-up.
Never lower the attachment or auxiliary tools other
than from sitting in the operator’s seat. Sound the
horn. Make sure that nobody is within the machine
operating range. Lower the attachment slowly.
Securely block and lock the machine every time you
leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary
operations for stopping as detailed in the Operation
and Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky
hanging walls, areas with overhead electric lines, and
slopes before stopping it at the end of the working
day.
Align the upperstructure to the tracks in order to allow
to easily get on and off the driver’s compartment.
Move all controls to the position specified for machine
stopping. Refer the Operation and Maintenance
Instruction Manual.
Never park on an incline without accurately blocking
the machine to prevent unexpected movement.
Follow stopping instructions contained in the
Operation and Maintenance Instruction Manual.
MAINTENANCE
GENERALITIES
19400 60406991
Carefully read the Operation and Maintenance
Instruction Manual before starting, operating,
maintaining, fuelling or servicing the machine in any
manner.
Read all safety plates mounted on the machine and

SAFETY PRECAUTIONS
observe instructions they contain before starting,
operating, repairing, fuelling or servicing the machine.
Do not allow unauthorised personnel to repair or
service the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
when required. Ask your employer about safety
regulations in force and protective equipment.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Never service the machine with someone sitting in the
driver’s seat, unless this person is an authorised
operator assisting in the maintenance being carried
out.
Keep the operator’s compartment, step plates, grab
rails and handles clear of foreign objects, oil, grease,
mud or snow to minimise the danger of slipping or
stumbling.
Clean mud or grease from your shoes before climbing
on the machine or driving it.
Never attempt to operate the machine or its
attachments from any position other than sitting in the
operator’s seat.
Keep the driver’s seat free from foreign objects,
especially if these are not secured.
Should it be necessary to move the attachment for
maintenance purposes, do not raise or lower the
attachment from any other position than sitting in the
operator’s seat. Before starting the machine or
moving its attachment, sound the horn and require
that nobody remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance purposes
using adequate external means as required by local
and national regulations. Do not allow anyone to
pass or stay near or below a raised attachment. If you
are not absolutely sure about your safety, do not stay
or walk under a raised attachment.
Do not place head, body, limbs, hands, feet or fingers
near articulated cutting edges deprived of the
necessary guards, unless they are suitably and safely
locked.
19400 60406991
Never lubricate, repair or adjust the machine with the
engine running, except when this is specifically
required by the Operation and Maintenance
Instruction Manual.
Do not wear loose clothing, jewellery near rotating
parts.
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When service or maintenance require access to
areas that cannot be reached from the ground, use a
ladder or step platform conforming to local or
national regulations to reach the working area. If
such means are not available, use machine grab
rails and steps. Always perform all service or
maintenance work with the greatest care and
attention.
Shop and/or field service platforms or ladders should
be manufactured and maintained in accordance with
local or national safety regulations in force.
Disconnect batteries and label all controls to warn
that service work is in progress, according to local
and national safety regulation requirements.
Block the machine and all attachments to be raised
according to local and national safety regulation
requirements.
Do not check or fill fuel tanks or install batteries near
burning or smoking materials and open flames due
to the presence of flammable vapours.
The fuel filler pipe nozzle must be constantly kept in
contact with the filler neck and this even before fuel
starts flowing in. Keep this contact from the
beginning to the end of the fuelling operation to
avoid possible generation of sparks due to static
electricity.
Use a truck or trailer to haul a failed machine.
Should it be necessary to tow it, provide for suitable
danger signals as required by the local norms and
regulations and observe recommendations given in
the Operation and Maintenance Instruction Manual.
Load/unload the machine on firm level ground
providing safe support to the wheels of the truck or
trailer. Use strong access ramps, with adequate
height and angle. Keep the trailer flatbed free of
mud, oil or slippery materials. Tie the machine
securely to the trailer and block carriages and
upperstructure.
Never align holes or slots using your fingers; always
use appropriate aligning tools.
Remove all sharp edges and burrs from re-worked
parts.
Use only approved and effectively grounded auxiliary
power sources for heaters, battery chargers, pumps
and similar equipment to reduce electrical shock
hazard.
Lift and handle heavy components using hoisting
devices of appropriate capacity. Ensure the parts are
supported by appropriate straps and hooks.
Use lifting eyes provided to this aim.
Pay attention to bystanders near the lifting area.
Never pour gasoline or diesel fuel into open
containers. Never use gasoline, solvents or other
flammable fluids to clean parts. Use proprietary
certified non-flammable, non-toxic solvents only.
When using compressed air to clean parts, wear
safety glasses with side shields. Limit pressure to
max. 2 bars, in accordance with local and national
safety regulations in force.
Do not run the engine of this machine in closed
buildings without proper forced ventilation capable to

SAFETY PRECAUTIONS
remove toxic exhaust gases concentrating in the air.
Do not smoke, nor allow open flames or sparks
nearby while refuelling the unit or handling highly
flammable materials.
Do not use open flames as light sources to look for
leaks or inspect anywhere on the machine.
Make sure that all mechanical tools provided are in
good condition at all times. Never use tools with
mushroomed or damaged heads. Always wear eye
protections with side shields.
Move with extreme care when working under, on or
near the machine or its attachments.
In case of attachment tests during which the engine
should be kept running, a qualified operator must sit
in the driver’s seat at all times while the mechanic is
at work.
Keep hands and clothes far OFF moving parts.
Stop the engine and move the safey lever to the lock
position before starting adjusting or repairing an
assembly.
Do not carry out any work on the attachment without
prior authorisation. Observe recommended
maintenance and repair procedures.
In case of field service, move the machine to level
ground and block it. If work on an incline cannot be
avoided, securely block the machine and its
attachments. Move the machine to level ground as
soon as possible. Do not twist chains and cables.
Never use a twisted chain or cable for lifting or
pulling. Always wear safety gloves to handle chains or
cables.
Be sure chains and cables are firmly fastened and
that the anchor point is strong enough to withstand
the expected load. Keep all bystanders clear of the
anchor point, cables or chains. Do not pull or tow
unless the operator’s compartments of the
machines involved are fitted with proper guards
against cable or chain backlash.
Keep the maintenance area clean and dry at all times.
Clean immediately all water and oil spillage.
Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment operating
range before starting or operating the machine and/or
its attachments. Sound the horn.
Rust inhibitors are volatile and flammable. Prepare
parts in well ventilated areas. Keep open flames
away. Do not smoke. Store containers in a cool well
ventilated place where they could not be reached by
unauthorised people.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welder’s equipment such as
dark safety glasses or mask, hard hat, protective
clothing, safety gloves and footwear always while
welding or arc-cutting. Wear dark safety glasses when
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SR2-1-6
you are near a welding in progress. Do not look the
welding arc without proper eye protection.
Become acquainted with all your jacking equipment
and their capacity. Ensure that the jacking point on
the machine is appropriate for the load applied. Also,
be sure the supports under the jack and between the
jack and the machine are appropriate and stable.
Any equipment supported by a jack represents a
possible hazard. Always support the load onto
appropriate blocking means as a safety measure
before proceeding with service or maintenance work,
in compliance with local or national safety regulations.
Metal cables produce steel splinters. Always wear
certified protection clothes such as safety gloves and
glasses while handling them.
Handle all parts carefully. Keep hands and fingers
away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves and footwear.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower
the attachment to the ground and relieve pressure
from all circuits prior to carrying out any type of
maintenance or repair work.
Do not service or repair the machine if it is parked
downhill. Consult the Operation and Maintenance
Instruction Manual for correct maintenance
procedure.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
injuries are most likely to occur. Pay attention to
prevent possible part movements by means of blocks
or by keeping clear of such zones when motion may
take place during maintenance or repair.
Move the hydraulic system lock safety lever to the
lock position when stopping the machine for whatever
reason.
Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.
TRANSFERS AND TRANSPORTATION
Before moving or transporting the machine, block
upperstructure swing to prevent accidental
movement.
Pay particular attention during transfer on inclines,
both uphill and downhill. Keep the bucket in a position
to provide a possible anchor point into the ground in
case of slipping.
During transfers on inclines, both uphill and downhill,
keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Never transfer the machine in the working site, in a
crowded area, or near people without having at least
19400 60406991
one person charged with hand-signals who could
guide the Operator.
Sound the horn to inform that you are about to move
off.
It is necessary to know load limits of bridges and
dimensional limits of tunnels. Such limits must never
be exceeded. You should also know machine height,

SAFETY PRECAUTIONS
width, and weight. Have a signal-man help you when
clearances are limited.
Check distance between boom/arm and dimensional
limits during transfer or transportation.
Rough terrain may cause the machine to sway and
roll to such an extent that boom/arm could get to
contact electric lines or other obstacles. Cross
obstacles at a right angle at low speed. Pay attention
to machine shaking when the centre of gravity
overcomes the obstacle.
Keep the bucket down at all times during transfers.
Drive with the lights on and use appropriate signals
and flags.
Get to know and respect local and national
regulations.
Consider boom/arm and upperstructure dimensions
while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine
weight. Always load and unload on level surface.
Tow the machine following the instructions contained
in the Operation and Maintenance Instruction Manual.
ENGINE
Do not run the engine in closed buildings without
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the
Operation and Maintenance Instruction Manual.
Keep the exhaust manifold and tube free from
combustible matters. Fit the machine with shields and
guards when working in the presence of combustible
matter free in the air.
Do not refuel with the engine running, especially if
hot, as this increases fire hazard in case of fuel
spillage.
Never attempt to check or adjust fan belt tensions
when the engine is running.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes
before servicing the engine.
ELECTRICAL SYSTEM
19400 60406991
Pay attention to connect connecting cables to correct
poles (+ to +) and (- to -) at both ends. Do not short-
circuit terminals. Thoroughly follow instructions given
in Operation and Maintenance Instruction Manual.
Always move the key-start switch in the lock position
before servicing or repairing the machine.
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SR2-1-7
Batteries contain SULPHURIC ACID. Protect the eyes
when working near the batteries against possible
sprays of the acid solution. Should acid contact skin,
eyes, or clothes, RINSE IMMEDIATELY IN WATER
FOR AT LEAST 15 MINUTES. Immediately seek
medical attention.
Battery released gas is highly flammable. Leave
the battery compartment cover open during
recharging to improve ventilation. Never check battery
charge by placing metal objects across the posts.
Keep sparks or open flames away from batteries. Do
not smoke near the battery to prevent explosion
hazard.
Before any maintenance or repair, make sure that
there are no fuel or electrolyte leaks from the
batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to avoid
accidental explosions due to build-up of explosive gas
released during charging.
Disconnect batteries before working on the electrical
system or carrying out any other type of work.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to
penetrate the skin. Always check any suspected
pressure leaks using a piece of cardboard or wood.
Do not use hands. If injured by escaping fluid, obtain
medical attention immediately or serious infection or
reaction may develop.
Stop the engine and ensure pressure is relieved from
all systems before removing side panels, housings,
guards and covers. See the Operation and
Maintenance Instruction Manual.
Always use gauges of adequate capacity for pressure
testing. Refer to the Operation and Maintenance
Instruction Manual or Repair Manual.
TOOLS
Always keep head, body, limbs, feet, hands, and
fingers away from the bucket and attachments, when
in the raised position.
Prior to any maintenance or repair work, install all
supports necessary to this aim according to local and
national safety regulations.
In case the attachment is to be operated for
maintenance or repair purposes, do so exclusively
while sitting in the driver’s seat. Sound the horn
before starting the machine or moving the attachment.
Require that nobody remain near the machine. Raise
the attachment slowly.
Do not use the machine to transport loose objects,
unless proper securing devices are provided.
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SR2-1-8
SAFETY PRECAUTIONS

TYRES AND WHEELS

Make sure that the inflation pressure of the tyres is

according to the specifications issued by the Manufacturer
and check it periodically.

Should the pressure be changed, stand on the side of the

tyre at a safe distance.

Pressure check operations must be performed with

unloaded machine and cold tyres.
Never use reconditioned tyre rims, since eventual
weldings, heat-treatments or repairs not performed
correctly can weaken the wheel, thus causing subsequent
damages or dangers.

Do not perform torch cutting or welding operations on rims

with tyres installed.
Spare tyres must be inflated only as far it is necessary to
keep the rim components assembled; remember that when
not installed on the disc, a tyre inflated to maximum
pressure can explode.

Before operating on tyres, block all wheels, front and rear.

After lifting the machine with the cylinders, block it with
stands according to current safety rules and regulations.

Deflate the tyres before removing them.

Before removing objects from the tyre tread, deflate it.

Do not inflate tyres with flammable gas: they may

cause explosions and serious personal injuries.

After each shift check for loose screws and/or rim

mounting brackets. If necessary, tight them according
to the instructions herein contained.

19400 60406991

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SR2-2-1
SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

This is your SAFETY ALERT SYMBOL.

When you see this symbol on your machine or in this

Manual, be alert of the potential for personal injury.
Follow recommended precautions and safe operating
practices.

F3264

UNDERSTAND SIGNAL WORDS

In this Manual you will find the following words:

DANGER, WARNING, CAUTION, DANGER
referring to different hazard risks.

These words are always accompanied by the safety WARNING

alert symbol.

DANGER: indicates an imminent hazardous situation CAUTION

which, if not avoided, will result in death or serious injury.

WARNING: indicated a potential hazardous situation IMPORTANT

which, if not avoided, could result in death or serious
injury.
NOTE
CAUTION: indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate
injury.

IMPORTANT: indicates a situation which, if not avoided,

may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

This Manual also contains this symbol accompanying

instructions for correct behaviour as regards
environmental protection.
21599 60406991

F5041
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SR2-2-2
SAFETY PRECAUTIONS

FOLLOW SAFETY INSTRUCTION

Carefully read and follow all safety signs on the machine

and all safety messages in this manual.

Safety signs should be installed maintained and

replaced when necessary.

If a safety sign or this manual is damaged or missing,

order a replacement from your dealer in the same way
you order other replacement parts (be sure to state
machine model and serial number when ordering).

Learn how to operate the machine and its controls

correctly and safely.
F1437
Allow only trained, qualified, authorized personnel to
operate the machine.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair

the function and/or safety and affect machine life.

The safety messages in this SAFETY PRECAUTIONS

chapter are intended to illustrate basic safety procedures
of hydraulic excavators. However it is impossible for
these safety messages to cover every hazardous
situation you may encounter.
If you have any questions, you should first consult your
supervisor before operating and servicing the machine.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.

Keep the first-aid kit and fire extinguisher on hand.

Thoroughly read and understand the label attached to
the fire extinguisher to use it properly.
Establish emergency priority procedures to cope with
fires and accidents.
21599 60406991

Keep emergency numbers for doctors, ambulance

service, hospitals and fire department posted near the
telephone.
F1440
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SR2-2-3
SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.
Operating equipment safely requires the full attention
of one operator. Do not wear radio or music headphones
while operating machine.Wear close fitting clothing and
safety equipment appropriate for the job.
Standard safety equipment includes:
- A hard hat
- Safety shoes
- Safety glasses, goggles, or face shield
- Heavy gloves
- Hearing protection
- Reflective clothing
F1438
- Wet weather clothing
- Respirator or filter mask.
Do not take chances. Wear whatever is needed for the
job at hand.

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment

or loss of hearing.

Wear a suitable hearing protective device such as earmuffs

or earplugs to protect against constant or uncomfortably
loud noised.
F1439

FASTEN SEAT BELT

Should the machine overturn, the operator may become

injured and/or thrown from the cab. Not only, the operator
may be crushed by the overturning machine resulting in
serious injury or even death.

Prior to operating the machine, thoroughly examine belt

webbing, buckle, and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
Be sure to remain seated with the seat belt securely
21599 60406991

fastened at all times when the machine is in operation to

minimise injury hazard in case of accident. F3261
After a significant accident, replace the seat belts even
though they do not look damaged.
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SR2-2-4
SAFETY PRECAUTIONS

INSPECT THE MACHINE

Inspect the machine carefully every day or work-shift

by an attentive visual inspection of machine outside prior
to starting it to prevent damages and personal injuries.

In the walk-around inspection, be sure to cover all points

detailed in the Chapter “MAINTENANCE”, paragraph
“EXTERNAL VISUAL INSPECTION”.

F1441

USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain
a three-point contact with the steps and handrails and
face the machine. Do not use any controls as hand-
holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine.
F1442

ADJUST THE SEAT

Adjust the seat whenever changing operators. Be sure

that the operator can fully depress the pedals with his
back against the seat back.
If not, move the seat forward and check again.
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SR2-2-5
SAFETY PRECAUTIONS

OPERATE ONLY FROM OPERATOR'S SEAT

Avoid possible injury or machine damage. Do not start

the engine by shorting across starter terminals.
NEVER start the engine while standing on ground. Start
the engine only from operator’s seat.

F4041

KEEP RIDERS OFF MACHINE

Only allow the operator on the machine. Keep riders

off.
Riders on machine are vulnerable to injury such as being
struck by foreign objects or being thrown off the
machine.
Riders also obstruct the operator’s view, resulting in
unsafe operation.

F2444

AVOID POWER LINES

Serious injury or death can result from contact with

electric lines.

In case of works near air electrical lines respect the

necessary safety distances:

Operation Voltage Safety distance

21599 60406991

up to 1000 V 1.0 m
from 1 kV to 110 kV 3.0 m
from 110 kV to 220 kV 4.0 m
F2445
from 220 kV to 380 kV 5.0 m
unknown 5.0 m
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SR2-2-6
SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS

To avoid back-over and swing accidents:

Always look around before you back up and swing the
machine. Be sure that everyone is in the clear.
Keep travel alarm in working condition (if equipped).

Always be alert for bystanders moving into the work

area. Use horn or other signal to warn bystanders before
moving machine.

A person could stand behind the machine, in a dead

area, not visible from rearview mirrors. Before backing
up, make sure nobody is standing in that area. F1447

Use a signal person when backing up if your view is

obstructed. Always keep signal person in view.

Use hand signals when work conditions require signal

person.

No excavator or backhoe motions shall be made unless

signals are clearly understood by both signalman and
operator.

Learn the meaning of all flags, signs, and markings used

on the job and confirm who has the responsibility for
signaling.

When operating in potential dangerous areas, or in

areas with low visibility, use a person for machine shifts.

Before starting machine shifting, warn people near the

working area by means of the horn.
F3625
Keep windows, mirrors, and lights clean and in good
condition.
F5822

Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.
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SR2-2-7
SAFETY PRECAUTIONS

DIG WITH CAUTION

Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting
in serious injury or death.

Before digging, check the location of cables, gas lines,

and water lines.
Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic cable
should be accidentally severed, do not look into the
end. Doing so may result in serious eye injury.
Contact local authorities and/or the utility companies
directly (electric power, gas, telephone, water, sewers,
telecommunications, etc.) to obtain information about F2446
underground utility lines.

MOVE AND OPERATE MACHINE SAFELY

Bystanders are in danger of being run over.

Confirm the location of bystanders before moving,
swinging, or operating the machine.

Always keep the travel alarm in good working condition.

(if equipped).
It warns people when the machine starts to move.
F2447
Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate
hand signals before starting the machine.

RULES FOR ROAD TRANSFER

The machine is equipped with safety locks to be used

for road transfer.
When transferring the machine:
- Locate upper carriage towards swinging front axle.
Insert upperstructure antiswing lock.
- Locate cylinders as shown in homologation
configuration.
- Lock cylinders (cocks, reference marks).
- Lift stabilizers and dozing blade (if equipped).
- Unlock equipment control levers shifting safety
device lever to lock position.
On the road follow the rules regulating traffic.
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During road transfers always disconnect front axle lock.

F5823
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SR2-2-8
SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

Clear all persons from area of operation and machine
movement.
Make sure worksite footing has sufficient strength to
firmly support the machine.
When working close to an excavation, operate the
machine with che chassis frame positioned
perpendicular to the cliff face, so that the machine can
more easily evacuate if the cliff face collapses.
Confirm that your machine is equipped with a F.O.P.S.
(Falling Object Protective Structure) cab before working
in areas where there is the possibility of falling stones
or landslides.
When digging deeply, avoid hitting bottom of boom or
bucket cylinder hoses against the ground.
Use the bucket only for digging. To avoid accidents, do F2448

not use it as a jack hammer or wrecking ball.

WORKING ON SLOPES

Never go down on slopes with gearbox in neutral. You

might loose control and cause serious injuries or death.
WRONG
When going down on slopes, use a low gear. In this
way the engine is used as brake and holds the machine
without overloading brakes.

When working on a slope and the warning light for fuel

insufficient level lights up, fill the tank immediately.

Due to machine inclination, the engine can suct air and

stop suddendly, causing a serious danger to the
operator and the persons behind the machine.

If the engine stops suddenly, apply brakes and lower F5825

immediately the bucket to the ground.

CORRECT
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F5824
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SR2-2-9
SAFETY PRECAUTIONS

AVOID TIPPING

When operating on a slope, keep bucket low to ground

and close to machine. Point chassis frame uphill to avoid
tipping.
To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to the
machine.
- Reduce machine operating speed to avoid tipping
or slipping.
- Avoid changing direction when travelling on grades.
- Never attempt to travel across a grade steeper than
15 degrees.
- Reduce swing speed as necessary when swinging
loads.

Be careful when working on frozen ground.

- Temperature increases will cause the ground to F5826

become soft and make ground travel unstable.

DRIVE MACHINE SAFELY

Before starting the machine, read carefully the "use and

instructions manual" to get familiar with pedals and
levers.

Before moving the machine, confirm which way to move

travel pedals/levers for the corresponding direction you
wish to go.

When traveling up or down a grade, keep the bucket in

the direction of travel, approximately 20 to 30 cm (A)
above the ground.
F2449

BEWARE OF EXHAUST FUMES

Engine exhaust fumes can cause sickness or death.

If you must operate in a building, be sure there is

adequate ventilation.
21599 60406991

Either use an exhaust pipe extension to remove the

exhaust fumes or open doors and windows to bring
enough outside air into the area.

F1446
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SR2-2-10
SAFETY PRECAUTIONS

PROTECTION OF CAB

In case of operation of the excavator under conditions

where land slides with falling rocks or any conditions
where there is a potential falling of objects of different
nature that could endanger the operator, it is necessary
to install a FOPS (Falling Object Protective Structure)
to protect the cab.

F2450

OPERATE WITH CAUTION

If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may results as well.

Take care to avoid hitting overhead obstacles with the

boom or arm.

F2451

AVOID INJURY FROM RUNAWAY

ACCIDENTS
Death or serious injury may result if you attempt to
mount or stop a moving machine.

To avoid runaways:
Select level ground when possible to park machine.

Lower bucket to the ground.

Lower dozing blade (blade) to the ground.
Lock upperstructure swing.
Stop the engine and remove the key from the key switch.
Pull pilot control shut-off lever to LOCK position.

Block both tyres and lower bucket to the ground,

thrusting the bucket teeth into the ground if you must
park on a slope.
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Park a reasonable distance from other machines.

F2452
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SR2-2-11
SAFETY PRECAUTIONS

PARK MACHINE SAFELY

Before working on the machine:

- Park machine on a level surface.
- Lower bucket to the ground.
- Move turret swing lever to lock position.
- Run engine at slow idle speed without load for 3
minutes.
- Turn key switch to OFF to stop engine. Remove key LOCK
F5042
from switch.
- Pull pilot control shut-off lever to LOCK position.
- Allow engine to cool.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments.

F2440

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur

causing serious injury or death.

F5043

PROVIDE SIGNALS FOR JOBS INVOLVING

A NUMBER OF MACHINES

For jobs involving several machines, provide signals

commonly known by all personnel involved.

Also, appoint a signal person to co-ordinate the job site.

Make sure that all personnel obey the signal person’s

directions.
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F3614
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SR2-2-12
SAFETY PRECAUTIONS

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

Instinctive travel pedal operation may result in serious

injury and even death.

Before driving the machine, be aware of the

undercarriage position relative to the operator’s seat.

If swinging/steering axle is located behind towards the

counterweight, the machine will move reverse when
F5044
control pedal is moved forwards.

KEEP PERSONNEL CLEAR FROM

WORKING AREA

A person may be hit severely by the swinging front

attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

Keep all persons clear from the area of operation and

machine movement.
F5045

Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.

NEVER MOVE THE BUCKET OVER ANY

ONE

Never lift, move, or swing bucket above anyone or a

truck cab.

Serious injury or machine damage may result due to

bucket load spill or due to collision with the bucket.
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F5046
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SR2-2-13
SAFETY PRECAUTIONS

AVOID UNDERCUTTING

Never undercut or the footing might collapse.

Before starting to work, make sure of the excavator

control direction.

If the footing starts to collapse and if sufficient retreat is

not possible, do not panic.
F5047
Often, the machine can be secured by lowering the front
attachment.

SAFETY TRANSPORTING

The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

- Be sure to obser ve local regulations when

transporting the machine on public roads.

- Provide an appropriate truck or trailer for transporting

the machine. F5048

Take the following precautions when loading/unloading

the machine:

- Select firm level ground.

- Be sure to use a loading dock or ramp.

- Be sure to have a signal person when loading/

unloading the machine.

- Always turn the auto-idle (A/I) switch off when

loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.

- Always select the slow speed mode with the travel

speed selector.

In the high speed mode, travel speed may automatically

21599 60406991

WEDGES
increase. BLOCKS
RAMPS
F5827
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SR2-2-14
SAFETY PRECAUTIONS

- Avoid steering while driving up or down the ramp as

it is extremely dangerous.

If steering is unavoidable, first move back to the

ground or flatbed, modify travelling direction, and
begin to drive again.

- Operate the safety lever but do not operate any other

control except travel control when driving up or down
the ramp.

- The top end of the ramp where it meets the flatbed

is a sudden bump. Take care when traveling over it. F5828

- Prevent possible injury from machine tipping while

the upperstructure is rotating.

- Keep the arm tucked under and rotate the

upperstructure slowly for best stability.

- Securely fasten machine frame using chains or

cables.

Refer to “Transport” chapter in this manual for details.

F5829

F5830
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F5831
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SR2-2-15
SAFETY PRECAUTIONS

PRACTICE SAFE MAINTENANCE

Understand service procedures before doing work.

Keep work area clean and dry.

Never lubricate or service the machine while it is

moving.
Keep hands, feet and clothing from power-driven
parts.

Before servicing the machine, park the machine on a

level surface.

If maintenance procedure must be performed with

engine running, do not leave machine unattended.
F1458

If the machine must be raised, keep a 90 to 110°

between boom and arm. Securely suppor t any
machine elements that must be raised for service
work.
Never work under a machine raised by the boom.

Inspect certain parts periodically and repair or replace

as necessary.

Keep all parts in good condition and properly installed.

Fix any damage immediately. Replace worn or broken
parts.

Remove any building of grease, oil, or debris.

Disconnect the ground cable (-) from the batteries
before servicing electrical systems or welding on the
machine.

F5832
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SR2-2-16
SAFETY PRECAUTIONS

CLEAN TRASH FROM MACHINE

Keep engine compartment, radiator, batteries, hydraulic

lines, fuel tank, and operator’s station clean.
Temperature in engine compartment may go up
immediately after engine is stopped.
BE ON GUARD FOR FIRES DURING THIS PERIOD.
Open access door (s) to cool the engine faster, and
clean engine compartment.

F1460

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious

injury.

Before performing any work on the machine, apply the

"Maintenance in progress" tag (see SAFETY PLATES
in this Chapter). This tag can be applied to the left-
hand control lever, safety lever or cab door.

F2431

CLEAN THE MACHINE REGULARLY

Remove any grease, oil or debris build-up to avoid

possible injury or machine damage.

Do not spray water or steam inside the cab.

F1462

STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious injury
or death.

Securely store attachments and implements to prevent

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them from falling. Keep playing children and bystanders

away from storage area.

F1463
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SR2-2-17
SAFETY PRECAUTIONS

SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing

the machine first.

Always lower the attachment or tool to the ground before

working on the machine.
If you must work on a lifted machine or attachment,
securely support the machine or attachment.

Do not support the machine on cinder blocks, bollow

tires, or props that may crumble under continuous load.
Do not work under a machine that is supported solely
by a jack.

F3634

PREVENT PARTS FROM FLYING OFF

Tyres are charged with pressure.

Tyre and/or rim parts burst may result in serious injury

or death.

Only skilled staff can replace tyres.

Always keep the correct tyre pressure.

Never exceed the recommended pressure when inflating F3635

tyres.

Slow down or stop and let tyres get cool.

When adjusting tyre pressure, keep at a certain distance

and protect yourself. Use an extension equipped with a
quick connection for the valve handling.

Always stay behind the tyre when adjusting pressure.

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SR2-2-18
SAFETY PRECAUTIONS

STARTING THE ENGINE WITH BOOSTER

BATTERIES

Battery gas may explode causing serious damages and

injuries.

If the engine is to be started using booster batteries,

ensure to comply with all procedures detailed in the
chapter “OPERATING INSTRUCTIONS”.

The operator should be sitting in the driver’s seat to

keep the machine under control when the engine starts.
Starting the engine with booster batteries is a two man F1464
operation.

Do not recharge batteries that have been stored in the

cold for a long time as they might explode. Heat them
at 15°C.

Mistakes in following procedures detailed for starting

the engine with slave batteries may cause the batteries
to explode or machine to move unexpectedly.

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SR2-2-19
SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.

Keep bystanders away from the working area before

striking any object, to avoid personal injury.

F1466

STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious injury.

To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating parts.

F1467

SUPPORT MACHINE PROPERLY

Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment.

Do not support the machine on cinder blocks, hollow

tiles, or props that may crumble under ontinuous load.

Do not work under a machine that is supported solely

21599 60406991

by a jack. Follow the procedures in this manual.

F1468
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SR2-2-20
SAFETY PRECAUTIONS

PREVENT BURNS

After operation, the engine coolant is hot and is under

pressure. Hot water or steam are contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
Be sure to stop the engine, and let engine and radiator
cool.
Slowly loosen the cap to release pressure after the
system has cooled, then remove it.

Engine oil, gear oil and hydraulic oil also become hot
F1477
during operation.
The engine, hoses, lines and other parts become hot
as well.
Wait for the oil and components to cool before starting
any maintenance or inspection work. The hydraulic oil
tank is pressurized. Again, be sure to release all
pressure before removing the cap.

F1469

REMOVE PAINT BEFORE WELDING OR

HEATING

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch.

Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.

If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with F1446

soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
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SR2-2-21
SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by applying heat

near pressurized fluid lines, resulting in severe burns
to yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lined
or other flammable materials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or other
materials when engaging in welding, soldering, etc.

F1470

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

Do not weld or flame cut pipes or tubes that contain

flammable fluids. Clean them thoroughly with
nonflammable solvent before welding or flame cutting
them.
F5840

AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.

Relieve the pressure by moving the control levers

several times.
Tighten all connections before applying pressure.
Wear a shield or protection glasses to protect your eyes.

Search for leaks with a piece of cardboard; take care

F3636
to protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor familiar with this

type of injury immediately.

Any fluid injected into the skin must be surgically

removed within a few hours or gangrene may result.
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F1471
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SR2-2-22
SAFETY PRECAUTIONS

PREVENT FIRES

1. Check for oil leaks:

Fuel, hydraulic oil and lubricant leaks can lead to

fires that may result in serious injury.

Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damaged
oil-cooler, and loose oil-cooper flange bolts, for oil
leaks.

Search for leaks with a piece of cardboard.

F3638
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Do not use your bare hand to check for oil leaks.

Tighten, repair or replace any missing, loose or

damaged clamps, lines, hoses, oil-cooler and oil
cooler flange bolts.

Do not bend or strike high-pressure lines.

Never install bent or damaged lines, pipes or hoses.

2. Check for shorts:

Short circuits can cause fires that may result in

serious injury.

Clean and tighten all electrical connections.

Check before each shift or after eight (8) hours of

operation for loose, kinked, hardened or frayed
electrical cables and wires.

Check before each shift or after eight (8) hours of

operation for missing or damaged terminal caps.

DO NOT OPERATE MACHINE if cable or wires are

loose, kinked, etc.

Tighten, repair or replace any loose or damaged

electrical cables, wires, and terminal caps before
operating the machine.

3. Clean flammables:

Spilled fuel and oils, and accumulated coal dust and

other flammables may cause fires and
seriouspersonal injury.
21599 60406991

Prevent fires by keeping machine clean every day.

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SR2-2-23
SAFETY PRECAUTIONS

4. Check key-start switch:

If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
Always check key-start switch function before
operating the machine every day:
- Start the engine and run it at slow idle.
- Turn the key-start switch to the OFF position to
confirm that the engine stops.

If any abnormalities are found, be sure to repair them

before operating the machine.

5. Check heat shields:

Damaged or missing heat shields may lead to fires. F1464

Damaged or missing heat shields must be repaired

or replaced before operating the machine.

HANDLE CHEMICAL PRODUCTS SAFETY

Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.

Check the MSDS before you start any job using a

hazardous chemical. That way you will know exactly
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.

See your authorized dealer for MSD’S (available only

F1465
in English) on chemical products used with your
machine.
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SR2-2-24
SAFETY PRECAUTIONS

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste on
FIAT-HITACHI excavators includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.

Do not pour waste onto the ground, down a drain, or

into any water source.
F1473
Air conditioning refrigerants escaping into the air can
damage the Ear th’s atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.

Obtain information on the proper way to recycle or

dispose of waste from your local environmental or
recycling center, or from your authorized dealer.

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.

Avoid the hazard by:

Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.

If you spill acid on yourself:

Flush your skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush your eyes with water for 10-15 minutes.
Get medical attention immediately. F1474

If acid is swallowed:
Drink large amounts of water of milk.
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Then drink milk of magnesia, beaten eggs, or

vegetable oil.
Get medical attention immediately.
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SR2-2-25
SAFETY PRECAUTIONS

HANDLE FLUIDS - AVOID FIRES

Handle fuel with care; it is highly flammable.

Do not refuel the machine while smoking or near open
flame or sparks.
Always stop engine before refueling machine. Fill fuel
tank outdoors.

Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and F1475

debris.

Do not store oily rags; they can ignite and burn

spontaneously.

F1457

SERVICE MACHINE SAFELY

Tie long hair behing you head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.

F1476

SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool

enough to touch with bare hands.
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F1477
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SR2-2-26
SAFETY PRECAUTIONS

DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the environment

and ecology. Before draining any fluids, find out the
proper way to dispose of waste from your local
environmental agency.

Use proper containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.

DO NOT POUR oil into the ground, down a drain, or

into a stream, pond, or lake. Observe relevant F1478

environmental protection regulations when disposing

of oil, fuel, coolant, brake fluid, filters, batteries, and
other harmful waste.

WORK IN A CLEAN AREA

Before starting a job, clean the work area. Remove

objects that may be a safety hazard to the mechanic or
bystanders.

F5835

ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
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F1480
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SR2-2-27
SAFETY PRECAUTIONS

USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.

Use power tools only to loosen threaded tools and

fasteners.

For loosening and tighening hardware, use the correct

size tools. Do not use U.S. measurement tools on metric
fasteners. Avoid bodily injury caused by slipping
wrenches.
F1479

Use only recommended replacement parts. (See Parts

Catalog).

EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the following

way:

Stop the engine by turning the key-start switch to the

OFF position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.

F3638
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SR2-2-28
SAFETY PRECAUTIONS

NOTES:

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SR2-3-1
SAFETY SIGNS

TRIPLE ARTICULATION VERSION

1. Decal, equipment safe area of operation.

2. Decal, counterweight safe area of operation.

F5049

8. Hooking points. 8
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F5050
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SR2-3-2
SAFETY SIGNS

MONOBLOC VERSION

1. Decal, equipment safe area of operation.

2. Decal, counterweight safe area of operation.

2
1

F5834

8. Hooking points.
8
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F5050
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SR2-3-3
SAFETY SIGNS

3. Decal, no walking. 5

4. Decal, window lock. 6

5. Decal, reference to manuals.

6. Decal, warning speed descending a slope.

7. Card, maintenance in progress. 12

8. Hooking point. 11
>6%

9. Decal, controls lock/unlock (safety lever).

10. Decal for engine hood warning. F5125

11. Boom and arm movement warning plate (triple

articulation version). Cab right side, inner

12. Boom movement warning plate (monobloc

version).
LOCK

13. Hydraulic oil pump bleeding plate. 9

7 LOCK

F5124

F2431
Card, maintenance in progress
10 3

4
STOP

714XXXXX I-D
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F5126 13

F5127
Rear glass cab, inner
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SR2-3-4
SAFETY SIGNS

1 – Decal, equipment safe area of operation

Make sure that exposed personnel in the area of

operation are clear of the machine before moving
the machine or its attachments. Sound horn.
Background: yellow
Stripe and lettering: black

F2455

2 – Decal, counterweight safe area of op-

eration

Make sure that exposed personnel in the area of

operation are clear of the machine before moving
the machine or its attachments. Sound horn.
Background: yellow
Stripe and lettering: black

F2438

3 – Decal, no walking

Prohibition of walking on engine cowling.

Ignoring this prohibition could cause damages to
the engine cowling, as well as endangering the
safety of persons not obeying this rule.
Background: transparent
Edging and lettering: black

F2436
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SR2-3-5
SAFETY SIGNS

4 – Decal for window lock

It indicates the danger of injury deriving from incorrect

block of front windshield in open position.
Background: yellow
Edge and graphics: black

F2437

5 – Decal, reference to manuals

It is positioned inside the cab to recommend the

careful reading of the Operation and Maintenance
Instruction Manual prior to proceeding with the
starting, operation, maintenance, refuelling or other
interventions on the machine.
Background: yellow
Stripe and lettering: black

F2456

6 – Decal, warning speed descending a

slope

In case it is necessary to descend a slope with

gradients up to or higher than 6%, the use of a
reduced speed is recommended.
In such a case, a reduced speed must be selected
pushing the button “turtle” located on the right side
control panel; in doing so a perfect operation of the
machine is ensured, also in such operating F2457

conditions.
21599 60406991

Background: white and red

Edge and lettering: black
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SR2-3-6
SAFETY SIGNS

7 – Card, maintenance in progress

It is compulsory, for maintenance operators, to apply

a card warning about incomplete efficiency of the
machine and the presence of personnel performing
maintenance in unseen positions. This card must
be located on the left pilot control or the cab door.
Background: yellow
Lettering: black
Edges: red

F2431

8 – Decal, hooking point

Indication of the eight hooking points (two on front

axle, two on rear axle, two on counterweight, two on
lower frame) to be used for towing or lifting the
machine.
Background: white
Edging and lettering: black

F3254

9 – Decal, controls lock/unlock

It indicates the position that the safety lever can have

when the engine is running.
It is imperative that should the operator abandon the
cab with engine running, even for a very short time, LOCK
the safety lever must be moved to LOCK position.
Controls are disconnected and any accidental
equipment movement is impossible.
Background: white
Stripe and lettering: black
21599 60406991

F2440
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SR2-3-7
SAFETY SIGNS

10 – Decal for engine hood warning

It indicates you have to stop the engine before

opening the hood.
Danger of serious injury due to rotating parts such
as fans, pulleys and belts.
Background: transparent
Stripe and graphics: black

F2435

11 – Boom and arm movement warning

plate (triple articulation version)

It shows the danger represented by the bucket hitting

the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: yellow
Stripe and lettering: black

F5051

12 – Boom and arm movement warning

plate (monobloc version)

It shows the danger represented by the bucket hitting

the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: transparent
Stripe and graphics: black
21599 60406991

F5051
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SR2-3-8
SAFETY SIGNS

13 – Hydraulic oil pump bleeding plate

It indicates that air should be bled from the pumps

after every hydraulic oil change.
Danger of pump seizure.
Background: yellow
Stripe and graphics: black

F3536

21599 60406991
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INDEX EX135W - 3 - 1

SECTION 3 SPECIFICATIONS

INDEX

Group 1 - GENERALITY ............................................................................................... SP3-1-1

1.1 Introduction
1.2 Basic components of the wheeled excavator with monobloc
1.3 Basic components of the wheeled excavator with articulated arm
1.4 Identification data

Group 2 - TECHNICAL SPECIFICATIONS ................................................................... SP3-2-1

2.1 General specifications

2.2 Dimensions - monobloc version
2.3 Digging performances - monobloc version
2.4 Dimensions - triple articulation version
2.5 Digging performances - triple articulation version
2.6 Dimensions - monobloc version with clamshell bucket
2.7 Digging performances - monobloc version with clamshell bucket
2.8 Dimensions - triple articulation with clamshell bucket
2.9 Digging performances - triple articulation with clamshell bucket
2.10 Bucket usefulness depending on boom
2.11 Lifting capacity

Group 3 - FILLING CHART ........................................................................................... SP3-3-1

21599 60406991
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21599 60406991
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SP3-1-1
GENERALITY EX135W

1. GENERALITY

1.1 INTRODUCTION

The hydraulic excavator is essentially made of three main components: TURRET, WHEEL BASE and FRONT
EQUIPMENT.

This machine is entirely controlled by an hydraulic system.

The mechanical energy of the engine is transformed into hydraulic energy, actuating cylinders and hydraulic
motors, where it is reconverted into mechanical energy to perform an operation. In other words, travelling,
swinging the turret, digging and all other operations are performed using hydraulic power.

TURRET

WHEEL FRAME

FRONT
EQUIPMENT
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SP3-1-2
GENERALITY EX135W

1.2 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH MONOBLOC

6 7 9 8 10 11

15 16 14 13 12

F5057

2 1 17

1. Bucket 10. Counterweight

2. Link rod 11. Hydraulic oil tank
21599 60406991

3. Linkage 12. Wheel assembly

4. Bucket cylinder 13. Rear axle
5. Dipstick 14. Cab and operator’s compartment
6. Digging cylinder (penetration) 15. Carriage
7. Monobloc 16. Front axle
8. Fuel tank 17. Blade
9. Lifting cylinder
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SP3-1-3
GENERALITY EX135W

1.3 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH ARTICULATED ARM

6 7 8 19 9 10 11

4
12
3
13

14

F5056

2 1 18 16 17 15

1. Bucket 11. Counterweight

2. Link rod 12. Hydraulic oil tank
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3. Linkage 13. Wheel assembly

4. Bucket cylinder 14. Rear axle
5. Dipstick 15. Cab and operator’s compartment
6. Digging cylinder (penetration) 16. Carriage
7. Articulated arm 17. Front axle
8. Fuel tank 18. Blade
9. Lifting cylinder 19. 1st arm (lifting)
10. Positioning cylinder
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SP3-1-4
GENERALITY EX135W

1.4 IDENTIFICATION DATA

15

13 12 11 10

14

F5058

1.4.1 WHEELED EXCAVATOR MARKING DECAL

21599 60406991

1. Machine technical type. 9. Not applicable.

2. Homologation number. 10. Not applicable.
3. Identification number. 11. Machine manufacturing year.
4. Machine total mass allowable. 12. Engine power in kW.
5. Max. load on front axle. 13. Absorption coefficient.
6. Max. load on rear axle. 14. Frame identification number.
7. Not applicable. 15. Identification decal: diesel engine type and serial
8. Not applicable. number.
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SP3-2-1
TECHNICAL SPECIFICATIONS EX135W

2. TECHNICAL SPECIFICATIONS
2.1 GENERAL SPECIFICATIONS

2.1.1 ENGINE

Net power to the flywheel (80/1269/EEC) ....... 76 kW

Make and model .......................... CUMMINS B 3.9C
Type ................. 4-stroke diesel type, direct injection,
turbocharged
Rated speed ............................................... 2100 rpm
Number of cylinders .................................................4
Displacement .............................................. 3922 cm3
Bore and stroke ..................................... 102x120 mm
«Auto/Idling» device with engine automatic reset to
minimum speed with controls in neutral. The device can
be disconnected by hand with a suitable knob in cab.
Electronic engine speed control through selector F7503
knob.
Button E (Economy) to reduce fuel consumption.
Selectable automatic reset to minimum speed “Auto-
Idle” (A/I) with controls in neutral.
Automatic cold start device (fitted as a standard) for
easy start-up down to -18°C outside temperature.

2.1.2 HYDRAULIC SYSTEM

“Load Sensing” closed centre hydraulic system for

equipment control with CSS (Cross Sensing System)
type swing upperstructure circuit for perfectly
simultaneous movements.
SPC (Swing pressure Control) device for perfect
controllability and high operation comfort in
upperstructure acceleration/stop.
A.H.S. (Advance Hydraulic System) circuit for perfectly
controllable and simultaneous movements.
CCS (Cold Climate System): for immediate excavator
efficiency in cold climates.
FPS (Flow Pump Saving) and SLS (Shock Less System)
circuits to minimize exhaust oil quantity and to
guarantee smooth operation and even movements
also if the control levers are moved abruptly.
Main pumps: two variable displacement pumps.
equipment/travel control pump
- maximum output ....................................... 191 I/min
- maximum operating pressure ..................... 300 bar
upperstructure swing control pump
- maximum output ......................................... 58 I/min
- maximum operating pressure ..................... 310 bar
Cylinders:
- lifting (triple articulation) .........................................2
bore x stroke ....................................... 105x980 mm F6861
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- lifting (monobloc) ...................................................2

bore x stroke ....................................... 115x955 mm
- penetration .............................................................1
bore x stroke ..................................... 115x1140 mm
- bucket ....................................................................1
bore x stroke ......................................... 95x995 mm
- positioner (triple articulation only) ..........................1
bore x stroke ....................................... 150x715 mm
Cylinders with hydraulic end-of-stroke. Less equipment
stress and higher operation comfort.
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SP3-2-2
TECHNICAL SPECIFICATIONS EX135W

2.1.3 DRIVE LINE

With automatic or manual control, variable displacement

hydraulic motor and double speed (working and speed)
synchronized gearbox for gear shift during excavator
motion. A computer on board controls gear shift enable
from transfer to working speed. It guarantees the
maximum comfort and safety for the operator. A selector
in the cab allows to choose reduced transfer speed. F7504

The transmission is equipped with TDC (Travel motor

Displacement Control) device to reduce the use of
parking brakes during transfers on slopes.

Max slope that can

Speed range km/h be overcome (%)
working: fast 0 ÷ 8.8 65
- slow 0 ÷ 2.9
transfer: fast 0 ÷ 33.6 25
-slow 0 ÷ 11

2.1.4 CONTROLS

Fully power-assisted: two ergonomic single-lever control

levers operate digging equipment and upperstructure
swing.
A double pedal controls travel and positioner.

F2492
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SP3-2-3
TECHNICAL SPECIFICATIONS EX135W

2.1.5 AXLES

New axles complete with disc-type brakes in oil bath.

Fixed rear axle.
Swinging front axle: swing ................................... ±7°
Front axle can be hydraulically locked in any position;
some safety valves lock the axle in case of failure.

F6863

2.1.6 UPPERSTRUCTURE SWING

Swing motor ........................................... axial pistons

Swing brake .............. automatic operation, disc-type
Final reduction unit ......oil-immersed planet. red. gears
Swing joint ........................................... in grease bath
Swing speed .................................................... 9 rpm

F6864
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SP3-2-4
TECHNICAL SPECIFICATIONS EX135W

2.1.7 BRAKES

Service brakes: pedal-operated with hydraulic

transmission on 1st and 2nd axle wheels, with two
independent circuits equipped with power
accumulators; multiple-disc mechanical brakes in oil
bath on both axles.
Parking brake: spring-type mechanical brake acting
on transmission, with multiple disc-connection and
integrated transmission; hand-operated by a switch
and electrical transmission with oil power accumulation.
Emergency brake: in case case of breakage or failure
of a part of service brake device transmission, it is
possible to stop the machine progressively by system
sectioning.

F10579

2.1.8 STEERING SYSTEM

Fully hydraulic, power-steering operated, driven by a

gear pump.
Steering axle ........................................................ 35°
Outer steering radius with twin tyre
with spacer 10.00x20 ..................................7200 mm

F2496

2.1.9 ELECTRICAL SYSTEM

Operating voltage ................................................ 24V

Maintenance-free series-mounted batteries ............ 2
- capacity ........................................................ 100 Ah
Alternator ........................................................... 50 A
Starter motor ..................................................... 4 kW
19400 60406991
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SP3-2-5
TECHNICAL SPECIFICATIONS EX135W

2.1.10 TIRES

Installation Inflation
Type Brand
dual pressure

10.00 R 20 NB-38
BARUM coupled 7,5 bar
ML 16 PR

18 R 19,5 MICHELIN single 7 bar

10.00 R 20 NB-38
BARUM coupled 6,5 bar
14 PR

600/40 - 22,5 ALLIANCE single 6 bar

F5680i
F2497

2.1.11OPERATING WEIGHTS (APPROX.)

Weight in working configuration: machine with 2090

mm dipstick, 900 mm bucket, twin tyres, full tank and
operator.
Version:
Triple hydraulic articulation ........................ 13150 kg.
Monobloc ................................................... 12850 kg.
Weight changes with equipment:
F6866
Rear stabilizers ......................................... + 1150 kg.
Front stabilizers ......................................... + 1100 kg.
Front and rear stabilizers .......................... + 2250 kg.
2490 mm. dipstick ......................................... + 50 kg.
2990 mm. dipstick ....................................... + 100 kg.
Front blade .................................................. + 750 kg.
Rear blade .................................................. + 750 kg.
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SP3-2-6
TECHNICAL SPECIFICATIONS EX135W

DIMENSIONS (mm) - (MONOBLOC VERSION)

Version with individual tyres: 18R 19.5 XF-TL

F5061

F5837

F5838

VERSIONS W/
A B C D E F
ARM *G H I L M N O P Q R
21599 60406991

2090 2500 930 1210 1930 7550 2730 2000 3020 3635 365 4120 1050 2250 1010 7670 7630

2490 2500 930 1210 1930 7550 2870 2000 3020 3635 365 4120 1050 2250 1010 7670 7630

2990 2500 930 1210 1930 7550 3280 2000 3020 3635 365 4020 1050 2250 1010 7570 7630
F5692i

* With twin tyres 10.00-20 NB38ML: ................................................................................................. 1972 mm

individual tyres 600/40-22.5: .................................................................................................. 1950 mm
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SP3-2-7
TECHNICAL SPECIFICATIONS EX135W

DIGGING PERFORMANCES - (MONOBLOC VERSION)

F5062

Arm mm 2090 2490 2990

A mm 8020 8365 8860

A' mm 7830 8185 8685

B mm 4800 5200 5700

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B' mm 4560 4985 5520

C mm 8610 8805 9170

D mm 6260 6460 6820

E mm 2700 2765 3020

F mm 3780 4180 4600

F5690i
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SP3-2-8
TECHNICAL SPECIFICATIONS EX135W

DIMENSIONS (mm) - (TRIPLE ARTICULATION VERSION)

Version with individual tyres: 18R 19.5 XF-TL

F5061

F5913

F5914

VERSIONS W/
A B C D E F
*G H I L M N O P Q R
21599 60406991

ARM
2090 2500 930 1210 1930 7785 2765 2000 3020 3635 365 4355 1050 2550 1010 7905 7865

2490 2500 930 1210 1930 7750 2870 2000 3020 3635 365 4320 1050 2550 1010 7870 7830

2990 2500 930 1210 1930 7595 3365 2000 3020 3635 365 4165 1050 2550 1010 7715 7675
F5685i

* With twin tyres 10.00-20 NB38ML: ................................................................................................. 1972 mm

individual tyres 600/40-22.5: .................................................................................................. 1950 mm
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SP3-2-9
TECHNICAL SPECIFICATIONS EX135W

DIGGING PERFORMANCES - (TRIPLE ARTICULATION VERSION)

F5064

Arm mm 2090 2490 2990

A mm 8330 8690 9190

A' mm 8150 8520 9020

B mm 5230 5620 6120

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B' mm 5045 5440 5960

C mm 9390 9670 10100

D mm 6975 7255 7690

E mm 2650 2810 3170

F mm 3300 3700 4200

F5694i
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SP3-2-10
TECHNICAL SPECIFICATIONS EX135W

DIMENSIONS (mm) - (MONOBLOC VERSION WITH CLAMSHELL BUCKET)

Version with individual tyres: 18R 19.5 XF-TL

F5061

F5991

F5992

VERSIONS
A B C D E F
* H I L M N O P Q R
21599 60406991

W/ARM
2090 2500 930 1210 1930 7390 3070 2000 3020 3635 365 3960 1050 2550 1010 7510 7470

2490 2500 930 1210 1930 7240 3285 2000 3020 3635 365 3810 1050 2550 1010 7360 7320

2990 2500 930 1210 1930 7100 3805 2000 3020 3635 365 3670 1050 2550 1010 7220 7180
F5691i

* With twin tyres 10.00-20 NB38ML: ................................................................................................ 1.972 mm

individual tyres 600/40-22.5: ................................................................................................. 1.950 mm
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SP3-2-11
TECHNICAL SPECIFICATIONS EX135W

DIGGING PERFORMANCES - (MONOBLOC VERSION WITH CLAMSHELL BUCKET)

10 9 8 7 6 5 4 3 2 1 0
10

1 F5919

8
10 9 8 7 6 5 4 3 2 1 0

Working diagram with 2090 mm dipstick

Working diagram with 2490 mm dipstick
Working diagram with 2990 mm dipstick

Arm mm 2090 2490 2990

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Digging depth mm 5825 6225 6695

Max. outreach mm 7540 7890 8380

Max. dump height mm 5110 5310 5695

F6043i
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SP3-2-12
TECHNICAL SPECIFICATIONS EX135W

DIMENSIONS (mm) - (TRIPLE ARTICULATION VERSION WITH CLAMSHELL BUCKET)

Version with individual tyres: 18R 19.5 XF-TL

F5061

F5921

F5922

VERSIONS W/
A B C D E F
ARM *G H I L M N O P Q R
21599 60406991

2090 2500 930 1210 1930 7630 2905 2000 3020 3635 365 4200 1050 2550 1010 7750 7710

2490 2500 930 1210 1930 7590 3080 2000 3020 3635 365 4160 1050 2550 1010 7710 7670

2990 2500 930 1210 1930 7465 3725 2000 3020 3635 365 4035 1050 2550 1010 7585 7545
F6169i

* With twin tyres 10.00-20 NB38ML: ................................................................................................. 1972 mm

individual tyres 600/40-22.5: .................................................................................................. 1950 mm
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SP3-2-13
TECHNICAL SPECIFICATIONS EX135W

DIGGING PERFORMANCES - (TRIPLE ARTICULATION VERSION WITH CLAMSHELL

BUCKET)

10 9 8 7 6 5 4 3 2 1 0
10

1 F5918

8
10 9 8 7 6 5 4 3 2 1 0

Working diagram with 2090 m dipstick

Working diagram with 2490 m dipstick
Working diagram with 2990 m dipstick

Arm mm 2090 2490 2990

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Digging depth mm 3550 6740 7240

Max. outreach mm 7855 8215 8710

Max. dump height mm 5865 6135 6565

F6170i
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SP3-2-14
TECHNICAL SPECIFICATIONS EX135W

BUCKET USEFULNESS DEPENDING ON ARM

BUCKET ARM LENGTH mm

Capacity dm3
Weight with
Type Width mm SAE J 296 2090 2490 2990
teeth kg
(ISO 7451)
R 500 230 230
R 750 410 270
MONOBLOC
VERSION

R 850 480 300

R 900 520 340
R 1000 590 400
R 1200 745 450
TRIPLE ARTICULATION

R 500 230 230

R 750 410 270
VERSION

R 850 480 300

R 900 520 340
R 1000 590 400
R 1200 745 450
F6168i

NOTE: The data refer to a machine in cross-digging position with rear blade in raised position.

Material max. specific weight Material max. specific weight

1200 kg/m3 1800 kg/m3

Material max. specific weight

1500 kg/m3

R: backhoe buckets
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SP3-2-15
TECHNICAL SPECIFICATIONS EX135W

2.11 LIFTING CAPACITY

2.11.1READING KEY FOR THE LIFTABLE LOAD CHART LOCATED IN THE CAB

714XXXXX XXXX kg 7
XXXXXX
2
1 3
1 2 XX

4 5 6

XXX
XXX
XX

XXX/XXX bar

F6843

1. Boom length.

2. 2nd boom length “LD”, alternatively.

3. Load distance from pivot point.

4. Maximum liftable load in tons to roll-over limit as per ISO

10567 Standards.

5. Maximum liftable load in tons at maximum distance from

pivot point.

6. Maximum working distance from pivot point.

7. Counterweight weight.

8. Main relief valve/hydraulic safety valves pressure setting.

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SP3-2-16
TECHNICAL SPECIFICATIONS EX135W

LIFTABLE WITH BUCKET LOAD CHART

EX135W
NOTE: Lift loads as per ISO 10567 Standards (75%
stability, 87% hydraulic system).

max. lift max

EX135W (Monobloc) 3m 4.5 m 6m 7.5 m
load distance

2090 mm
Z2 5.6* t 2.5 * t 1.9 t — 1.5 t 6.9 m
arm Z1 4.7 t 2.5 t 1.7 t — 1.4 t 7.0 m
(bucket 0.52 m3)
Z3 4.2* t 2.5 t — — 1.7 t 6.0 m

4600 mm 2490 mm
Z2 4.8* t 3.0 t 1.9 t — 1.3 t 7.3 m
arm Z1 4.7 t 2.5 t 1.7 t — 1.2 t 7.4 m
boom (bucket 0.52 m3)
Z3 4.7 t 2.5 t 1.6 t — 1.5 t 6.4 m

2990 mm
Z2 — 3.1 t 2.0 t 1.3 t 1.2 t 7.8 m
arm Z1 4.7 t 2.5 t 1.7 t 1.2 t 1.1 t 7.9 m
(bucket 0.41 m3)
Z3 4.6 t 2.5 t 1.6 t — 1.3 t 7.0 m
F5668i

* Value limited by machine hydraulic capacity.

max. lift max

EX135W (Triple articulation) 3m 4.5 m 6m 7.5 m
load distance

2090 mm
Z2 5.6* t 2.7* t 1.9 t — 1.4 t 7.1 m
arm Z1 4.6 t 2.5 t 1.7 t — 1.3 t 7.2 m
(bucket 0.52 m3)
Z3 4.5* t 2.5 t 1.7 t — 1.6 t 6.2 m
1950 3100
2490 mm
Z2 4.9* t 2.9 t 2.0 t — 1.3 t 7.5 m
mm mm arm Z1 4.7 t 2.5 t 1.7 t 1.3 t 1.2 t 7.6 m
(bucket 0.41 m3)
boom positioner Z3 4.7 t 2.5 t 1.7 t — 1.5 t 6.6 m

2990 mm
Z2 — 2.6* t 2.0 t 1.4 t 1.2 t 8.0 m
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arm Z1 4.7 t 2.5 t 1.7 t 1.2 t 1.1 t 8.1 m

(bucket 0.23 m3)
Z3 4.6 t 2.5 t 1.6 t — 1.3 t 7.2 m
F5669i

* Value limited by machine hydraulic capacity.

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SP3-2-17
TECHNICAL SPECIFICATIONS EX135W

LIFTABLE AT THE HOOK LOAD CHART

EX135W

NOTE: Lift loads as per ISO 10567 Standards (75%

stability, 87% hydraulic system). Load at the hook
(hook, reverse cylinder, bucket, rod, idler gear, etc.
excluded).

NOTE: If is necessary to lift of a load with the machine

equipped with some or all the above mentioned parts
(bucket, hooks, etc.), subtract their weight from the
weights shown on the chart. This is done to calculate
the lifting working capacity.

max. lift max

EX135W (Monobloc) 3m 4.5 m 6m 7.5 m
load distance

Z2 5.2* t 3.2 t 2.2 t — 1.8 t 6.7 m

2090 mm
arm
Z1 5.2 t 2.9 t 2.0 t — 1.8 t 6.8 m
Z3 5.3* t 2.9 t — — 2.2 t 5.7 m

4600 mm Z2 5.9* t 3.2* t 2.2 t — 1.7 t 7.0 m

2490 mm
arm
Z1 5.2 t 2.9 t 2.0 t — 1.6 t 7.1 m
boom
Z3 5.2 t 2.9 t 2.0 t — 2.0 t 6.1 m
Z2 5.2* t 3.3* t 2.2 t 1.5 t 1.5 t 7.5 m
2990 mm
arm
Z1 5.1 t 2.9 t 2.0 t 1.5 t 1.5 t 7.6 m
Z3 5.1 t 2.8 t 2.0 t — 1.7 t 6.6 m
F6831i
* Value limited by machine hydraulic capacity.

max. lift max

EX135W (Triple articulation) 3m 4.5 m 6m 7.5 m
load distance

Z2 5.2* t 3.3 t 2.2 t — 1.8 t 6.8 m

2090 mm
arm
Z1 5.2 t 2.9 t 2.0 t — 1.7 t 6.9 m
Z3 5.2 t 2.9 t — — 2.1 t 5.8 m
1950 3100 Z2 4.5* t 3.1* t 2.2 t — 1.7 t 7.2 m
mm mm 2490 mm
arm
Z1 5.1 t 2.9 t 2.0 t — 1.6 t 7.3 m
boom positioner Z3 5.1 t 2.9 t 2.0 t — 1.9 t 6.3 m
Z2 — 3.2* t 2.2 t 1.6 t 1.5 t 7.7 m
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2990 mm
arm
Z1 5.0 t 2.8 t 1.9 t 1.5 t 1.4 t 7.8 m
Z3 5.0 t 2.8 t 1.9 t — 1.6 t 6.8 m
F6832i

* Value limited by machine hydraulic capacity.

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SP3-2-18
TECHNICAL SPECIFICATIONS EX135W

NOTES:

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SP3-3-1
FILLING CHART EX135W

3. FILLING CHART

QUANTITY RECOMMENDED FLUIDS AND LUBRICANTS

COMPONENT TO BE FILLED MANUFACTURER'S INTERNATIONAL

Litres Ambra SPECIFICATIONS SPECIFICATIONS NOTES

Protective fluid to be
mixed with water at
50%. This mix has
31 AGRIFLU NH 900 A _ anticorrosive,
Engine cooling system antiscaling, and anti-
foaming properties;
does not freeze down to
-35° C.

Fuel tank 250 _ _ Diesel ASTM _

N. 2-D tipo TT

SUPER GOLD NH 330 G

15W-40 API CF-4/SG
Engine 9,5 CCMC D4
SUPER GOLD NH 324 G MIL-L-2104 E
10W-30

Gearbox 6,25 HYDRODEX NH 530 A ATF DEXRON IID _

TYPE

Swing reduction unit 3 HYPOIDE 90 NH 520 A API GL 5 _

MIL-L-2105 D

Front axle differential 8,4 HYPOIDE QFH 520 B API GL 5 _

Rear axle differential 8,4 90/LS MIL-L-2105 D
Axle reduction gears (each) 1,2

Attachment hydraulic system 130 HI-TECH 46 QFH 585/GR _ _

Pressure grease fittings
Swing joint teeth
Lithium-based grease
containing molybdenum
_ MG2 QFH 585/GR _ disulphide, resists to
8 kg (*) water, low temperature
and high loads; NLGI 2
consistency

Oil quantities shown are necessary for periodical changes following discharging and filling procedures detailed for each assembly.
(*) First filling only.

LUBRICANT TYPE OPERATING RANGE (AMBIENT TEMPERATURE °C)

TO BE FILLED Ambra VISCOSITY -30 -20 -10 0 10 20 30 40 50

Engine SUPER GOLD SAE 15W - 40

15W-40

SUPER GOLD SAE 10W - 30

10W-30

Gearbox HYDRODEX SAE 10W

21599 60406991

Swing reduction unit HYPOIDE 90 SAE 80W - 90

Front/rear axle differential HYPOIDE 90/LS SAE 80W - 90

Axle reduction gears (each)

Hydraulic system HI-TECH 46 ISO VG 46

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SP3-3-2
FILLING CHART EX135W

NOTES:

21599 60406991
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INDEX EX135W - 4 - 1

SECTION 4 SUPERSTRUCTURE

INDEX

Group 1 - SUPERSTRUCTURE.................................................................................... SS4-1-1

1.1 Main frame and counterweight

1.2 Engine group
1.3 Hydraulic oil reservoir
1.4 Fuel reservoir
1.5 Covers and protections
1.6 Cab group
1.7 Cab heater
1.8 Cab electric components
1.9 Chassis electric components
1.10 Superstructure maintenance
1.11 Superstructure hydraulic system piping
1.12 Flexible hoses and connections

Group 2 - HYDRAULIC PUMPS - O/P - D/A .............................................................. HYP4-2-1

2.1 Hydraulic pumps- O/P

2.2 Main pump - O/P
2.3 Secondary pump - O/P
2.4 Gear double pump - O/P
2.1 Main pump - D/A
2.2 Secondary pump - D/A
2.3 Gear double pump - D/A
21599 60406991

Group 3 - CONTROL VALVE - O/P - D/A ..................................................................... CV4-3-1

3.1 Control valve - O/P

3.1 Control valve - D/A

O/P = OPERATION PRINCIPLE (continued)

D/A = DISASSEMBLY AND ASSEMBLY
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INDICE EX135W - 4 - 1

INDEX (continued)

Group 4 - SWING DEVICE - O/P - D/A ....................................................................... SRD4-4-1

4.1 Swing device - O/P

4.2 Swing hydraulic motor - O/P
4.3 Swing reduction device - O/P
4.1 Swing hydraulic motor - D/A
4.2 Disassembly and assembly of swing reduction device - D/A

Group 5 - PILOT VALVES - O/P .................................................................................. PV4-5-1

5.1 Hand pilot valve - O/P

5.2 Travel pilot valve - O/P

Group 6 - CENTER JOINT - O/P - D/A ......................................................................... CJ4-6-1

6.1 Center joint - O/P

6.1 Disassembly and assembly of center joint - D/A

Group 7 - STEERING VALVE - O/P - D/A .................................................................... SV4-7-1

7.1 Steering valve - O/P

7.1 Steering unit disassembly and assembly - D/A

Group 8 - BRAKE PEDAL VALVE - O/P - D/A .......................................................... BRV4-8-1

8.1 Brake pedal valve - O/P

8.1 Maintenance - D/A

Group 9 - ACCUMULATORS - O/P - D/A ................................................................. ACC4-9-1

9.1 Accumulators - O/P

9.1 Disassembly and assembly of accumulator - D/A

Group 10 - SOLENOID VALVES - O/P - D/A ............................................................. SOV4-10-1

10.1 Selector solenoid valves - O/P

10.2 Services solenoid valves group - O/P

Group 11 - PRIORITY VALVE - O/P .......................................................................... PRV4-11-1

21599 60406991

11.1 Priority valve

O/P = OPERATION PRINCIPLE

D/A = DISASSEMBLY AND ASSEMBLY
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SS4-1-1

SUPERSTRUCTURE EX135W

1. SUPERSTRUCTURE

1.1 MAIN FRAME AND COUNTERWEIGHT

1.1.1 CONSTRUCTION

Main frame consists of center frame, bed (right, left) and tail frame.
They are welded together.
Swing device and control valve are installed to the center frame. Operator's cab and hydraulic oil tank are
mounted on the left bed.
Fuel tank is mounted on the right bed.
Engine, pumps and counter weight are mounted on the tail frame.

1.1.2 SPECIFICATIONS AND DATA

Main frame ............................................ 1080 kg

Counterweight ................................. 3340±30 kg

1 - Counterweight
2 - Bed (left)
3 - Tail frame
4 - Bed (right)

4
3

2
21599 60406991

F6931

1
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SS4-1-2

SUPERSTRUCTURE EX135W

1.2 ENGINE GROUP

1.2.1 CONSTRUCTION AND FUNCTION

Engine

The CUMMINS B3.9-C type engine is used in EX135W.

This engine is a 4-cylinder of 3992 cm3, water-cooled, direct injection chamber with turbo-charger diesel
engine.
The engine is mounted on the main frame through for elastic supports (two front and two rear) of a silent-block
type.

21599 60406991

F7505
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SS4-1-3

SUPERSTRUCTURE EX135W

Radiator

The coolant radiator is located in front of the engine, together with the oil heat exchanger and it is cooled by
the engine fan.
A temperature sensor of the coolant, inserted into the coolant radiator body, informs the operator, through a
specific indicator on the monitor located in the cab, that an excessive temperature has been reached.

1 - Oil radiator
2 - Coolant radiator
3 - Grid
4 - Shroud
5 - Coolant temperature sensor
6 - Expansion tank
7 - Level plug
8 - Filling plug

8
7
5

6
1
2
4
3
21599 60406991

F6867
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SS4-1-4

SUPERSTRUCTURE EX135W

Air cleaner

The air cleaner consists of a plate outer case (C), a main cleaning element (A), a relief filter element (B), an
outlet for an air clogging switch.
This machine is provided with an air cleaner warning lamp which lights up the monitor panel when the air
cleaner’s element becomes clogged.

C
B

A
21599 60406991

F7506
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SS4-1-5

SUPERSTRUCTURE EX135W

Exhaust gases silencer

The gases generated during the combustion are sent, through the turbocharger, to the exhaust silencer (1)
and from the latter, they are discharged through duct (2) away from the machine.

2
21599 60406991

F2503
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SS4-1-6

SUPERSTRUCTURE EX135W

1.2.2 SPECIFICATIONS

Engine

Mark and Model Cummins B3.9

Type diesel, 4 cycle, vertical on-line, overhead valves, direct
injection with turbo-charger, water cooled.

Numbers of cylinder; Borex stroke 4 (on line) - 102 x 120 mm (4.02 x 4.73 in)
Displacement 3920 cm3

Release sequence 1-3-4-2

Rotation direction Clockwise (viewed from fan side)

- Cooling system Water circulated by centrifugal pump

Temperature control Termostat: 83° C (181° F)

- Starting motor Pinion shift system

Voltage/Out put 24V/4 kw

- Generator AC generator belt drive

Voltage/Out put 24V/40 A

- Super charging system Turbocharger, forced lubrication

- Fuel system
Injection pump R. Bosch

Radiator

- Radiator area 44.73 dm2 (693.3 sq in)

- Water capacity 20.5 l (5.4 Gals)

Oil cooler

- Radiator area 39,4 dm2 (610.7 sq in)

- Oil capacity 6.5 l (1.43 Gals)

Air Filter

- Elements Two: main cleaning element and relief filter element

21599 60406991

- Air flow rate 6 ÷ 12 m3/min.

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SS4-1-7

SUPERSTRUCTURE EX135W

1.3 HYDRAULIC OIL RESERVOIR

1.3.1 LAY-OUT AND OPERATION

Oil reservoir

The oil reservoir pressurized to facilitate the oil suction, works also as an oil conditioner, since it cools it,
separates air from the oil and eliminates contaminating particles.
The reservoir includes: a full-flow filter oil (4) a suction filter oil (2), a steering oil reservoir filter (8), holding
and eliminating dust and foreign particles from the oil connected to an OK indicator on the control module.

2 - Suction filter
3 - Draining plug
4 - Total flow filter
5 - Hydraulic reservoir
6 - Level indicator
7 - Safety valve
7 8 - Steering filter
11 4 9 - Hydraulic oil level
10 sensor
10 - Valve
11 - Breather filter

5
6 9
8
21599 60406991

3 F6932
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SS4-1-8

SUPERSTRUCTURE EX135W

Full-Flow Filter

The full flow filter is used to filter the oil every time it
circulates in the hydraulic circuit. Its function is to keep oil
clean from dust and dirt particles. As the dirt accumulates
on outer wall of filter element, a different pressure from
inside and outside of the filter element takes place. An
high different pressure causes the filter relief valve to
open, in order to prevent the filter element breakage. RELIEF
VALVE
FILTER
ELEMENT

Caution: Replace the filter element immediately as

soon as the filter relief valve is opened,
otherwise the dirty oil will cause serious
damages to the hydraulic components.
However, replace the filter according to the
Operation and Maintenance Instruction
Manual.

FILTERED
OIL

(A) Hydraulic oil is filtered. (B) Hydraulic oil is not filtered but it is
released from relief valve.

CLOGGED FILTER

RELIEF SPRING
VALVE
21599 60406991

FILTER ELEMENT
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SS4-1-9

SUPERSTRUCTURE EX135W

Suction Filter

Suction filter is provided to take out foreign

matter before oil enters the pumps. SUCTION
FILTER

SUCTION PIPE

TO HYDRAULIC
MAIN PUMP

Hydraulic oil cap

In the cap there is a device which allows oil tank to be pressurized. Inside the cap there are an air cleaner and
two suction and exhaust valves. Air cleaner keeps and filters dust and outside particles which could damage
the valves and contaminate hydraulic oil. The suction and exaust valves prevent pump cavitation by sucking
or releasing air inside the oil tank and help to keep pressurization inside the tank.

When the pressure in port A becomes higher than that of port B, the valve exhaust will open to read the
pressure to port B.

If the pressure in the port B becomes higher than that of port A, the valve intake will open to read the
pressure to port A.

B B
EXHAUST INTAKE
VALVE VALVE
21599 60406991

A A
F6943
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SS4-1-10

SUPERSTRUCTURE EX135W

1.3.2 MAINTENANCE STANDARD

Refer to maintenance standard as described on Operator's Manual N. 604.03.561

1.3.3 SPECIFICATIONS

Oil tank

- Capacity 122 l (31.7 gals)

- Oil capacity 72 l (18.7 gals)
- Weight 94 kg (207 lbs)

Full-Flow Filter

- Type paper element

- Filtration area 14,000 cm2
- Max. filtration 10µ
- Oil flow rate 360 l/min
- Relief valve set pressure 7 kg/cm2

Suction Filter

- Filtration area 1.890 cm2

- Max. filtration 177 µ
- Oil flow rate 600 l/min

Air breather (in the oil cap)

- Max. filtration 10µ

- Filtration area 160 cm2
- Valve set: intake 0.04 ± 0.05 kg/cm2 at 1 l/min
exhaust 0.5 ± 0.04 kg/cm2 at 1 l/min
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SS4-1-11

SUPERSTRUCTURE EX135W

1.4 FUEL RESERVOIR

1.4.1 CONSTRUCTION AND FUNCTION

The fuel reservoir is equipped with a strainer in the filler neck and a level indicator, and is also equipped with
a fuel level sensor connected to the relevant indicator, a reserve indicator, located on the monitor in the cab.
For the sensor and indicator, refer to Section 9.

1.4.2 SPECIFICATIONS AND DATA

Capacity ................................. 250 l (65 gals)

Mass ..................................... 74 kg (163 lbs)

1 - Fuel reservoir
2 - Strainer
3 - Filler cap
4 - Fuel level indicator
5 - Fuel level sensor
3 6 - Draining valve
2 7 - Sedimentation filter (on engine)
1

4
5

7
21599 60406991

F7507
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SS4-1-12

SUPERSTRUCTURE EX135W

1.5 COVERS AND PROTECTIONS

1.5.1 VARIOUS COVERS ON THE SUPERSTRUCTURE

The various cowlings on the superstructure have the purpose of protecting the hydraulic components from
rain, dust and the danger of possible damages caused by external obstructions.

5
3

05

6
4
1

21599 60406991

2
1 - Pump cowling
F6934
2 - Pumps front door
3 - Tool box cover
4 - Control valve cowling
5 - Control valve front door
6 - Gas shock absorber
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SS4-1-13

SUPERSTRUCTURE EX135W

1.5.2 ENGINE COVER

The engine cover is installed to protect the engine from damages from external obstructions.

1 - Engine cover
2 - Lock
3 - Gas filled jack

1
3
21599 60406991

F6935
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SS4-1-14

SUPERSTRUCTURE EX135W

1.5.3 LOWER PROTECTION

The lower protections have the purpose of protecting the hydraulic components from dust and the danger of
possible damages caused by external obstructions.

1 - Lower protection, cab (front)

2 - Lower protection, cab (rear)
3 - Lower protection, oil reservoir
4 - Lower protection, pumps
5 - Lower protection, fuel reservoir
6 - Protection, water tank
7 - Protection, engine oil pump

5
6

3
3

1
2

7
4
F6936
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SS4-1-15

SUPERSTRUCTURE EX135W

1.6 CAB GROUP

1.6.1 CONSTRUCTION

The cab group includes: cab, seat, steering and controls column, floor plate and carpet. The entire group is
mounted on anti-vibration elastic blocks.

Cab

The cab is totally designed to suit the operator’s comfort, in accordance with ISO standards, with an optimized
sound proofing level. The dimensions of the glassed surfaces offer an excellent visibility in all directions.

5
6
5

7
2

4
3

F6937
21599 60406991

1 - Outer door opening handle

2 - Inner door opening handle
3 - Door locking mechanism in "open" position
4 - Door unlocking mechanism from "open" position
5 - Windshield locking latch in "closed" position
6 - Windshield locking latch in "open" position
7 - Lower windshield locking latch in "closed" position
8 - Windshield unlocking from "open" position
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SS4-1-16

SUPERSTRUCTURE EX135W

Operator’s seat

The operator’s seat has been designed to offer maximum comfort. It incorporates adjustable armrests, an
adjustable backrest angle, back support adjustment, longitudinal adjustment (forward and backward),
longitudinal shock absorbing adjustment. Also, it is equipped with a seat shock absorber system operating in
accordance with the weight of the operator.

1 - Weight shock absorber adjustment knob

2 - Fore-and-aft adjustment lever
3 - Fore-and-aft adjustment lever
7
4 - Lever for swing and height adjustment
5 - Back adjustment lever
6 - Armrest adjustment control lever 6
7 - Headrest adjustment control lever 4

5
1
2
3

F6938

Steering and control column

The controls for the operation of the machine

are grouped around the operator’s seat, inside
the cab.

1 - Monitor panel.
2 - Switch panel.
3 - Control pedals for travel/articulated arm. 17 11
6
4 - Lifting and bucket control lever. 18 12
5 - Control lever for dipstick and 10 23
upperstructure swing.
6 - Steering wheel.
7 - Brake pedal.
8 - Upperstructure swing lock. 1
9 - Seat 2
17 19
10 - Windshield wiper and washer control.
7 3
11 - Control for direction indicator and lights.
21 8
12 - Gear selection control. 20
13 - Hourmeter. 22 4
14 - Start-up key. 14
15 - Mode E (economy) switch. 5 15
21599 60406991

16 - Manual accelerator. 9 16
17 - Horn (2 positions).
F6939
18 - Emergency lights switch.
19 - Rotating beacon switch.
20 - Tipping device switch.
21 - Manoeuvre lock switch.
22 - Optional.
23 - Commutator: brakes and axle lock.
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SS4-1-17

SUPERSTRUCTURE EX135W

Floor plate

The control devices, the seat group as well as the heater are secured to the floor plate.
1 - Floor plate
2 - Floor mat
3 - Elastic supports

2
1
3

F6941
21599 60406991

Elastic supports

Four elastic supports ensure a solid mounting of the cab on the frame of the machine and, at the same time,
minimize the vibrations generated during the operation of the excavator.
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SS4-1-18

SUPERSTRUCTURE EX135W

1.7 CAB HEATER

1.7.1 Construction

The machine is provided with a cab heater which consist of hoses connected to engine and of a control
located on the right rear side of the cab.
Before the heater is switched on, open the water cocks on engine. When heating system is not in use, keep
the water cocks on engine block shut.

1 - Electric fan
2 - Valve control
3 - Cover
4 - Heater
5 - Manifold
6 - Heater control

5 6
5

5
2

1 4
3 3

F6940
21599 60406991

1.7.2 Specifications

Heating power ................................................................................................................. 4640 ± 10% Kcal/h

Air flow ............................................................................................................................... 510 ± 10% cum/h
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SS4-1-19

SUPERSTRUCTURE EX135W

1.8 CAB ELECTRIC COMPONENTS

(A) Cab electric components location.

(For further informations about electric components see section 8).

4 7

F6942

1 - Radio set
2 - Antenna
3 - Speaker
21599 60406991

4 - Windshield washer with electric motor

5 - Wiper motor
6 - Lighter
7 - Ceiling light
8 - Power supply connection 24V
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SS4-1-20

SUPERSTRUCTURE EX135W

(B) Cab electric control location.

1 - Left pilot valve switches

2 - Right pilot valve switches
3 - Monitor
4 - Control panel 1
5 - Starting key switch
6 - Switch for brake and axle lock
7 - Central panel
8 - Wiper switch
9 - Speed change control
10 - Light switch
11 - Horn buttons
12 - Emergency light switch

12
7
11
1
11
8

6
10

2
3
4

9
5
21599 60406991

F6949
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SS4-1-21

SUPERSTRUCTURE EX135W

1.9 CHASSIS ELECTRIC COMPONENTS

1.9.1 POWER SUPPLY AND STARTER

1
5
6
4 2
3 5

8
7 F6944

1 - Battery
2 - Ground cable
3 - Battery disconnection
21599 60406991

4 - Main fuse (80 A)

5 - Battery cable/Starter cable
6 - Start fuse (40A)
7 - Starter ground
8 - Starter motor
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SS4-1-22

SUPERSTRUCTURE EX135W

1.9.2 THROTTLE CONTROL AND ALTERNATOR

1 - SMC control unit

2 - EC motor
3 - APC 50 control unit
4 - Alternator

1
21599 60406991

F6945
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SS4-1-23

SUPERSTRUCTURE EX135W

1.9.3 SWITCHES AND SENSORS LOCATION

(A) Engine and radiator.

1 - Cooling level sensor

2 - Cooling temperature switch
3 - Cooling temperature sensor
4 - Engine oil pressure switch 1
5 - Engine oil level sensor

2
4

F7459

(B) Fuel tank and hydraulic tank.

1
21599 60406991

F6948

1
F2519

1 - Fuel level sensor 1 - Hydraulic oil level sensor

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SS4-1-24

SUPERSTRUCTURE EX135W

(C) Brake valve

1 - Accumulators control pressure switch

2 - Brake light control pressure switch
2

F11113

(D) Hydraulic system

1 - Pressure switch
2 - Pressure switch 5
3 - Pressure switch
4 - Pressure switch
5 - Pressure switch 4

3
1

F6947

(E) Air cleaner

1 - Air cleaner clogging pressure switch

19400 60406991

F2858
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SS4-1-25

SUPERSTRUCTURE EX135W

1.9.4 ROAD AND WORK LIGHTS LOCATION

1 - Direction light
2 - Head-light
3 - Direction light
4 - Tail light
5 - Reflector
7 - Work light
8 - Horn

1
2

F6946

5
4
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SS4-1-26

SUPERSTRUCTURE EX135W

1.9.5 SPECIFICATIONS

• BATTERY
- Voltage 12V
- Rating (20 h) 100 Ah
- Discharge current (- 18°C) 440A
- Weight with electrolyte 23 kg

• BOOM HEAD-LIGHT
- Voltage and watt Halogen 24V, 70 W

• ROAD HEAD-LIGHT
- Voltage and watt 24V, 4 W - 24V, 70 W

• ROAD TAIL LIGHT

- Voltage and watt 24V, 21 W

• DIRECTION LIGHT
- Voltage and watt 24V, 4 W

• CEILING LIGHT
- Voltage and watt 24V, 5 W

• RADIO
- Voltage 24V

• SPEAKER
- Allowable input (rated) 10 W
(max.) 20 W
- Rated impedance 4 ohm

• WIPER MOTOR
- Rated voltage and current 24V, 2 A
19400 60406991
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SS4-1-27

SUPERSTRUCTURE EX135W

1.10 SUPERSTRUCTUE MAINTENANCE

1.10.1 REMOVAL/INSTALLATION OF CAB

Removal

1 Position the machine with the bucket resting on

the ground.
Stop the engine.

F5352

2 Untighten nuts (2) to remove seat (1).

F7407

3 Untighten the three screws (6) and screws (4)

(quantity used 4) in the rear part of the cab and
remove rear object holder (5).
21599 60406991

4 Untighten screws (8) to remove rear protection (7).

F7408
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SS4-1-28

SUPERSTRUCTURE EX135W

5 Remove filter (20). Untighten screws (9) to remove

air duct (10) from the cab.

F7409

6 Disconnect cable connectors (11, relay), (12, an-

tenna, ceiling light, windshield wiper) and (13,
loudspeakers) in the cab rear part and ground cable
(14) inside the cab.

11

12

13
14

14
F7420

7 Disconnect windshield washer liquid tube (15) from

the tank located in the case behind the cab.
21599 60406991

F7410
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SS4-1-29

SUPERSTRUCTURE EX135W

8 Remove plugs (21) from air duct cover (16).

Untighten screws (17) to remove air duct cover (16).

F7413

9 Push air duct (18) towards the cab rear part until it
Duct coupling
comes out of the coupling and remove it.

F7414

10 Attach the cab to the hoist by using lifting belts.

C
B
21599 60406991

WARNING
Cab approx. weight: 250 kg.

F7415
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SS4-1-30

SUPERSTRUCTURE EX135W

11 Remove screws (19) and nuts (22).

F7416

12 Carefully remove the cab.

F7417

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SS4-1-31

SUPERSTRUCTURE EX135W

Install the cab

WARNING
Cab approx. weight: 250 kg.

1 Attach the cab to the hoist by using lifting belts.

Lift the cab and place it on the main frame.

F7417

2 Tighten screws (19) and nuts (22).

F7416

3 Install air duct (10) and secure it to the cab by means

of screws (9). Fit filter (20) to air duct (10).
21599 60406991

F7409
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SS4-1-32

SUPERSTRUCTURE EX135W

4 Connect cable connectors (11, relay), (12, antenna,

ceiling light, windshield wiper) and (13, loudspeakers)
in the cab rear part and ground cable (14) inside the
cab.
11

12

13
14

14
F7420

5 Connect windshield washer liquid tube (15) to the

tank located in the case behind the cab.

F7410

6 Install rear protection (7) and secure it with screws

(8).
21599 60406991

7 Install rear object holder (5) and secure it with

screws (6) and (4).

F7408
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SS4-1-33

SUPERSTRUCTURE EX135W

8 Push air duct (18) towards the cab front part and fit
it into the coupling duct.

Duct coupling

F7414

9 Install air duct cover (16) and secure it with screws

(17). Plug (21) access holes to screws (17).

F7413

10 Secure seat (1) with nuts (2).

21599 60406991

F7407
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SS4-1-34

SUPERSTRUCTURE EX135W

1.10.2 COUNTERWEIGHT REMOVAL/INSTALLATION

Removal

1 Swing the turret 90° with respect to the

undercarriage and position the equipment with the
bucket on the ground. F6873

Stop the engine.

2 Remove the engine cowling removing the four

screws (A) and the two jacks inside the engine
compartment.
Disconnect the lights electric connections.

3 Remove plugs (B) on the counterweights and

install the lifting eyes (M36) (M42).

From frames:
EX135W 77WM0087 (Monoboom)
EX135WT 77WT0097 (Triple arm) B
(M42) has been fitted.

F6875

4 Attach lifting slings to eyes.

Mass of counterweight: 3340 ± 30 kg

(M36)
(M42)
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SUPERSTRUCTURE EX135W

5 Remove the screws securing the counterweight/

frame.

6 Lift the counterweight, move it away and lower it

to the ground.
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Installation

1 Lift the counterweight and position it on the fra-

me in correspondence with the securing holes.

2 Tighten temporarily the four securing screws fra-

me/counterweight.

3 Lower the counterweight and tighten the screws

to torque.
Tightening torque: 115 ± 5 daNm

4 Remove the lifting eyes and reinstall plugs (B).

B
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F6875
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SUPERSTRUCTURE EX135W

5 Reconnect the electric connections to the lights;

install the engine cowling and the two jacks
tightening screws (A) of the hinges. A
Tightening torque: 9 ± 1 daNm

F6874
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1.10.3 SUPERSTRUCTURE REMOVAL/INSTALLATION

Removal

- Remove the cab as indicated in paragraph 1.10.1 of this chapter.

Remove the counterweight as indicated in paragraph 1.10.2 of this chapter.

- Remove the front equipment assembly, as indicated in section 6 of this Manual.

1 Drain the hydraulic oil from the reservoir.

Disconnect the hydraulic pipes from the spindle
of the central joint.

2 Disconnect the electric connection of the central

joint on the spindle side.

3 Secure lifting cables and blocks to the front and

rear of the main frame.
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Front side

Rear side
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SUPERSTRUCTURE EX135W

4 Lift slightly and set the cables under load, than

check that they do not interfere with the engine.

5 Remove the screws securing the ring gear.

6 Level the main frame actuating the blocks.

Lift the main frame.
Remove the frame from the undercarriage and
place it on the ground.
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Installation

1 Secure lifting cables and blocks to the front and

rear of the main frame.
Level the frame adjusting the blocks.
Lift the turret.

2 Place the turret on the undercarriage and mount

it mounting the screws of the ring gear.
Tighten temporarily the screws.

3 Lower the turret and tighten the screws securing

the ring gear.
Tightening torque: 33 ± 3 daNm.

4 Plug in the electrical connection of the central joint.

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5 Connect the hydraulic pipes to the central joint.

For the connection of the pipes, refer to the number on the

control valve corresponding to the single ports:

1-2 - Hydraulic power steering: .... tightening torque 45 Nm

3 - Draining: ................................. tightening torque 35 Nm
4-5 - Travel: ................................. tightening torque 240 Nm
6-7 - Stabilizers: ........................... tightening torque 45 Nm
8 - Front brake: ............................ tightening torque 35 Nm
9 - Rear brake: ............................. tightening torque 35 Nm
10 - X point: ................................. tightening torque 45 Nm
11 - Axle locking: ......................... tightening torque 35 Nm
12 - Piloting: ................................. tightening torque 35 Nm
13 - Selector: ............................... tightening torque 35 Nm
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1.11 SUPERSTRUCTURE HYDRAULIC SYSTEM PIPING

1.11.1 GENERALITIES

The pipes of the hydraulic systems can be generally identified as: main pipes, pilot pipes, brakes pipes and
steering pipes.

1.11.2 MAIN PIPES

The pumps group (main pump + swing pump), driven by the engine, sucts oil from the reservoir and pumps
it under pressure to the control valve, and in turn, reaches the actuators. All the operations relative to: travel,
turret swing, equipment operations are hydraulically controlled by a corresponding motor or hydraulic cylinder.
The connections between hydraulic reservoir, pumps group, control valve, motors and/or hydraulic cylinders
are obtained by a piping system defined as main pipes.

SUCTION AND DELIVERY PIPES

5
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F7427

1 - Main pump
2 - Swing pumps
3 - Control valve
4 - Hydraulic oil reservoir
5 - Accumulator
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Return pipes 1 - Control valve

3 - Hydraulic oil heat exchanger
4 - Swing motor
5 - Central joint

F7428

5
4

1
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F7429
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Travel and swing control pipes

1

1 - Control valve
2 - Swing motor/reduction unit
3 - Central joint

3
F7430

Front equipment cylinders control pipes

1 - Control valve 1
2 - Boom control pipes 5 4
3 - Arm control pipes 5 4
4 - Positioner control pipes
5 - Bucket control pipes

2
3 2
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3
3
F6950
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1.11.3 PILOT SYSTEM PIPES

The pilot system pipes include the suction and delivery pilot pump and the connection system between pilot
valves and control valve.

(A) Pilot valves connections

1 - Solenoid valves block

2 - Pilot valves (boom/bucket)
3 - Pilot valves (arm/swing)
4 - Pilot valves (travel/positioner)
5 - Diverter block
6 - Solenoid valves B3/B4
7 - Solenoid valves B1/B2

6
1

7
5

3
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4
F6951
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(B) Boom and bucket control.

2

1 - Control valve
2 - Pilot valve (boom/bucket)

F6952

(C) Arm and swing control

3

1 - Control valve
2 - Swing reduction unit
3 - Pilot valve (arm/swing)
4 - Solenoid valves (B1/B2) 4
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F6953
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(D) Return pipes

4
2

5
3

F6954
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1 - Hydraulic reservoir
2 - Central joint
3 - Solenoid valves block
4 - Diverter block
5 - Pumps
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1.11.4 STEERING PIPES

Construction

The steering pipes include the suction and delivery control and return.

- Suction pipes
The circuit between reservoir and pump is defined suction pipes. The steering pump sucks the oil from the
hydraulic reservoir through an appropriate filter mounted inside the reservoir itself.

- Delivery pipes
The circuit between the steering pump and the power steering is defined as delivery pipe.

- Control pipes
The circuit between the power steering valve and the steering cylinder is defined as control pipes.
When the steering wheel is turned to the right or to the left, oil delivered by the steering pump is distributed
by the power steering valve, in relation with the angle movement of the steering wheel supplying the steering
cylinder through the central joint.
The oil pressure is set at 140 bar by the pressure relief valve of the power steering valve.

- Return pipes
The circuit between power steering valve and hydraulic system is defined as return pipes.

1
4

2
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1 - Power steering valve

2 - Steering pump
3 - Central joint
4 - Hydraulic oil reservoir

F7432
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SUPERSTRUCTURE EX135W

1.11.5 BRAKES PIPES

Construction

The brakes pipes include the suction, delivery and discharge pipes. In this system, the hydraulic oil is taken
from the reservoir (6) by gear pump (1) and through filter (4) reaches the brake pedal valve (2).

From brake pedal valve (2) the oil is sent to accumulators (3) to priority valve (7) and from here to the services
solenoid valve (8) as well as accumulator (9).

From the brake pedal valve itself, the oil is sent to central joint (5).
The discharge pipe connects brake valve (2) with the hydraulic oil reservoir (6).

1 - Pilot/Brake pump
2 - Brake valve
3 - Accumulators 2
4 - Pilot filter 6
5 - Rotary joint
6 - Hydraulic oil tank
9 - Accumulator
10 - Pressure sensor
1

F11115

9
10
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3
3
5 F11114
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SUPERSTRUCTURE EX135W

1.12 FLEXIBLE HOSES AND CONNECTIONS

1.12.1 FLEXIBLE HOSES

Description

The flexible hoses for pressurized oil include three fundamental parts (fig. 1):

- A sub-layer of extruded and vulcanized elastomer.

- One or more layers of reinforcing metal insertions.

- An outer covering layer of vulcanized elastomer.

Reinforcing insertions
Covering layer
Sub layer

Fig. 1
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Standards

In fig.2 the arrangement of the forces acting on the hoses subject to an internal pressure is shown. The action
of these forces is entirely contained by the metalic insertions ensuring an adequate safety margin for the
explosion of the hose.
The safety margin for each hose is expessed as a ratio between the bursting pressure (ps) and the operating
pressure (pe): its entity depends upon the characteristics of the inner pressure, that could be:
- static practically constant
- dynamic, with cyclic variations in time
Normally, the following safety metric are considered:

with static pressure with dynamic pressure

ps ps
pe = pe =
2,5 ÷ 3 4

Cyclic variations of the inner pressure during time with a trapezium wave are adopted for the test of hoses in
accordance with the current standards.
ISO 3862 - 1980 and others (international)
SAE J343 (USA)
DIN 20024 (Germany)
The values of operating pressures are indicated in the specific sections, in correspondence with the technical
specifications of the single versions, together with the values of the bursting pressure.
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Fig. 2
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Technical specifications

DIN 20023 - 4SP

Inner duct made of synthetic rubber, cotton plait, reinforcement with four steel wire spirals, synthetic rubber
cover.
Usage: particularly suitable for hydraulic systems subject to high pressure changes under heavy operating
conditions.
Operating temperatures: - 40°C + 120°C (- 40°F + 250°F)
Connections: crimped.

Inner diameter mm 6 8 10 12 16 20 25 32 38 50

Outer diameter mm 21.4 24.6 28.2 32.2 39.6

Operating pressure bar 490 420 400 380 320

Bursting pressure bar 1780 1660 1520 1500 1320

Bending radius mm 180 230 250 300 340

DIN 20022 - 2ST

Inner duct made of synthetic rubber reinforced with double plated steel wire and synthetic rubber cover.
Usage: hydraulic piping under high pressure subject to pressure changes.
Operating temperatures: - 40°C + 100°C (- 40°F + 212°F)
Connections: crimped.

Inner diameter mm 6 8 10 12 16 20 25 32 38 50

Outer diameter mm 17.5 21.3 24.6 27.7 31.8 39.6 50.8 57.2 69.6

Operating pressure bar 400 350 300 250 225 175 165 135 95

Bursting pressure bar 1600 1420 1220 1015 895 720 635 510 385
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Bending radius mm 100 130 180 200 240 300 420 500 630
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SUPERSTRUCTURE EX135W

DIN 20022 - 1ST

Inner duct made of synthetic rubber reinforced with plated steel wire and synthetic rubber cover.
Usage: general hydraulic piping, crude oil, gasoline and lubricant oil, fuel oil and water.
Suitable for many applications : - 40°C + 100°C (- 40°F + 212°F)
Connections: crimped.

Inner diameter mm 6 8 10 12 16 20 25 32 38 50

Outer diameter mm 15.9 17.5 19.8 23.0 26.2 30.2 38.1 46.0 52.4 66.7

Operating pressure bar 230 230 210 175 145 125 100 75 50 42

Bursting pressure bar 975 975 815 730 520 430 385 275 210 210

Bending radius mm 100 115 130 180 200 240 300 420 500 630

DIN 20021 - 2TE

Inner duct made of synthetic rubber reinforced with plated steel wire and synthetic rubber cover.
Usage: general hydraulic piping, crude oil, gasoline and lubricant oil, fuel oil and water.
Suitable for many applications : - 40°C + 100°C (- 40°F + 212°F)
Connections: crimped.

Inner diameter mm 6 8 10 12 16 20 25 32 38 50

Outer diameter mm 13.4 14.9 16.5 19.7 23.9 27.0 34.4

Operating pressure bar 75 68 63 58 50 45 40

Bursting pressure bar 300 270 250 230 200 180 160

Bending radius mm 40 50 60 70 90 110 130

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SAE 100 R7

Nom. inner Nominal out. Toler. Max. op. Min. burst Min. bending radius at
diam. diam. press. press. operating press.
inch mm. mm. mm. bar bar mm.
1/8 4 8.4 ± .1 235 940 32
3/16 5 9 ± .1 212 850 40
1/4 6.6 11.9 ± .1 212 850 44
5/16 8.1 14 ± .15 190 760 50
3/8 9.8 16 ± .15 190 760 70
1/2 13 20 ± .15 167 670 100
5/8 16.3 23.5 ± .2 125 500 160
3/4 19.6 27 ± .2 102 410 180
1 26 34 ± .2 90 360 200

The types of hoses used are marked on the rubber covering with a symbol identifying the inner diameter and
the fabrication specification.

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Identification

The identification codes of hoses are stamped on the connecting sleeve.

Each hose has an identification code stamped on the sleeve.
If a hose is without marking and this cannot be traced on the spare parts catalog, describe the specifications
when ordering a replacement.
The specifications of a hose is identified by the inner diameter, length of the hose including the connections,
the type of connection (straight, 90°, 45°) the type of thread (metric, gas) or SAE flange.

Total length

Total length

Total length

direction angle

Angle in degrees
The direction angle is
measured anticlockwise,
starting from the nearest
connection directed
downward.
Anticlockwise
rotation direction

Fig. 3

The operating safety of hoses depends, at a great extent, from their correct mounting on the components of
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hydraulic systems, as well, allowing eventual position movements linear and angular or both, if required.
The installation must, in fact, be made in such a manner that the hoses are not subject - in any position - to
twisting , traction or excessive flexion effort. The latter data such to determine a reduction of the bending radius
beyond admissible limits.
In case of frequent movements, it is recommended to increase the minimum bending radius to avoid reducing
operating life.
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SUPERSTRUCTURE EX135W

1.12.2 TERMINAL CONNECTIONS OF HOSES

Description

The connections represent the sealing coupling system between the hose and the seat on the mechanical
group or component to which they are connected.
All the types fall under the principle that the bursting pressure of the hose can be reached, prior to the beginning
of leakages of fluid from the connections or the withdrawal of the hose from them.
In order to perform this principle it is necessary to ensure a permanent sealing between the sub layer of the
hose and the connection as well an efficient mounting of the connection on the hose.
The connections for hoses are of a pressed type when mounted on zinc and passivated carbon steel pipes.

Pressed connections are made of a ring nut and sleeve, properly dimensioned for the mounting on the hose
(fig.4).
After the mounting on the end of the hose, the sleeve is radially deformed, until a permanent mounting between
the various elements is obtained.
The great technical advantage of such a solution consists in a guaranteed optimized coupling between
connection and hose, particularly reliable also when pulsating pressures are involved.

Hoses are equipped with SAE connection.

Fig. 4
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SAE standard heavy and light type counter flanges

SAE 6000 counter flanges

for pressures up to 420 bar - 6000 psi

Description X Q T D E
SAE 6000 mm mm mm mm mm
1
/2 9,1 40,5 8,5 32,5 15,7
3
/4 11,9 50,8 10,5 42,0 19
1" 14 57,2 13 48,5 22,5
1"1/4 15,7 66,7 15 54,7 23,8
1"1/2 18,3 79,4 17 64,5 27
2" 22,3 96,8 21 80,0 36,5

SAE 3000 counter flanges

for pressures up to 210 bar - 3000 psi

Description X Q T D E
SAE 3000 mm mm mm mm mm

1
/2 8,6 38,1 8,5 31 12,7
3
/4 11,1 47,6 10,5 39 14,2

1" 13,2 52,4 10,5 45,3 14,2

1"1/4 15 58,7 12 51,5 14,2

1"1/2 17,8 69,8 13,5 61 15,7

2" 21,3 77,7 13,5 72 15,7

O-Rings for SAE 3000 & SAE 6000

counter flanges
Description I S
SAE 3000 e 6000 mm mm

1
/2 18,6 3,5
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3
/4 25 3,5

1" 32,9 3,5

1"1/4 37,7 3,5

1"1/2 47,6 3,5

2" 57,1 3,5

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SUPERSTRUCTURE EX135W

1.12.3 ADAPTOR CONNECTIONS

The connections of hoses to hydraulic components are made of adaptors.

Herebelow, the most common adaptors are listed.

Flanges with 2 - 3 - 4 mounting holes

Standard series
Dimensions in mm

Nominal dimension 10 12 15 20 25 26 31 32 40
of flanges

A max. 10 12 15 20 25 26 31 32 40

B ± 0,2 26 30 35 40 51 55 61 62 72,5

C ± 0,2 18,38 21,21 24,75 28,28 36,06 38,89 43,13 43,84 51,26

min. M5 M6 M6 M6 - M8 M10 M10 -

D
max. - M8 M8 M8 M10 - - M12 M12

E 39 47 52 57 73 73 87 87 98
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F 25 28 32 37 48 48 54 54 63

G min. 31,5 38 42 45 58 58 68 68 76

H Radius 6,5 8,5 8,5 8,5 11 9 12,5 12,5 12,5

ØI 13,10 15,08 18,72 23,81 31,42 32,92 37,69 37,69 46,4

O-Ring
S 2,62 2,62 2,62 2,62 2,62 3,53 3,53 3,53 3,53
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BSP (GAS) cylindrical thread

O-Ring seal and retaining washer

Dimensions in mm

Dimensions F 1/8"-28 1/4"-19 3/8"-19 1/2"-14 3/4"-14 1"-11 1"1/4-11 1"1/2-11

Pitch in mm. 0,91 1,34 1,34 1,81 1,81 2,31 2,31 2,31

Max. out. Ø 9,73 13,16 16,16 20,96 26,44 33,25 41,91 47,80

Min. inn. Ø 8,6 11,45 14,95 18,65 24,12 30,3 38,95 44,85

A 1 1,5 2 2,5 2,5 2,5 2,5 2,5

B 8 12 12 14 16 18 20 22

B1 13 18,5 18,5 22 24 27 29 31
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D7 9,7 13,2 16,8 21 26,5 33,3 41,9 47,8

D 15,5 19,5 24 28,5 35 43 52,5 58,5

D6 16,5 21,5 25,5 30 36,5 45 55 61

ØI 7,66 10,78 13,95 17,86 23,47 29,75 37,69 44,04

O-Ring
S 1,78 2,62 2,62 2,62 2,62 3,53 3,53 3,53
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Cylindrical metric thread

Dimensions in mm

Dimensions F 10x1 12x1,5 14x1,5 16x1,5 18x1,5 20x1,5 22x1,5 26x1,5 27x2 33x2 42x2 48x2

Max. out. Ø 10 12 14 16 18 20 22 26 27 33 42 48

Min. inn. Ø 8,9 10,3 12,3 14,3 16,3 18,3 20,3 24,3 24,8 30,8 39,8 45,8

A 1 1,5 1,5 1,5 2 2 2,5 2,5 2,5 2,5 2,5 2,5

B 8 12 12 12 12 14 14 16 16 18 20 22

B1 13,5 18,5 18,5 18,5 18,5 20,5 20,5 22,5 24 26 28 30

D7 10 12 14 16 18 20 22 26 27 33 42 48
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D 15,5 18,5 19,5 23 26 28 30 35 36 43 53 60

D6 16,5 20 21,5 24,5 27,5 30 31,5 36,5 37,5 45 55 62,5

ØI 7,66 9,13 10,78 13,10 15,08 17,13 18,72 23,47 23,4 29,75 37,69 44,04
O-Ring
S 1,78 2,62 2,62 2,62 2,62 2,62 2,62 2,62 3,53 3,53 3,53 3,53
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Installation of 90° adaptors, adjustable with locking nut.

BSP (GAS) or metric thread with retaining washer and O-Ring

Lock nut
Protection washer
Retaining washer
O-Ring

Lubricate the O-Ring smearing it with a light film of oil,

tighten the securing nut completely to free entirely the relief
of the thread and visually check that the protection washer
can reach the position indicated in the figure.

Mount the connection in the appropriate seat without forcing

it, until the protection washer and the retaining washer,
depending upon the type of fitting being performed, touch
the machined surface.

Correct the position rotating anticlockwise the connection

up to one turn max., to reach the desired position, than,
holding the position with a wrench, tighten the nut.
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1.12.4 TIGHTENING TORQUES FOR CONNECTIONS AND HOSES

Tightening torques of screws for SAE flanges

SCREWS TIGHTENING TORQUES

8G 10K

M6 11 Nm 15 Nm

M8 25 Nm 34 Nm

M10 47 Nm 65 Nm

M12 86 Nm 120 Nm

M14 135 Nm 190 Nm

M16 210 Nm 295 Nm

All tightening the torques listed above refer to screws mounted, previously lubricated by dipping into engine
oil.

SPECIFICATIONS 1) Hand tighten Q.ty 2 opposite screws with an air wrench at min. power.
2) Tighten manually with a wrench or an air wrench up to the nominal tightening
prescribed for the 2 screws diametrically opposite to the previous ones.
3) Tighten the two screws previously approached in the same manner.

Tightening torque of threaded connections

The tightening torques listed must be reduced by 25% in case the connection is mounted with the use of Teflon.

BSP (GAS) Tightening torque METRIC Tightening torque

1/8" 25 Nm M10 x 1 25 Nm

1/4" 50 Nm M12 x 1.5 30 Nm

3/8" 80 Nm M14 x 1.5 50 Nm

1/2" 140 Nm M18 x 1.5 90 Nm

3/4" 220 Nm M22 x 1.5 160 Nm

1" 370 Nm M27 x 2 285 Nm

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1"1/4 600 Nm M36 x 2 500 Nm

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Tightening torque for nuts of hose connections (Nm)

Warning: before mounting check the following points:

- Check that the securing bushes of the connections to the hose show clear signs of the pressing. Otherwise
discard the hose.

- The O-Ring on the tapered surface is perfectly efficient.

- Remove the sealing plugs and ensure that the connections are clean.

- Lubricate the thread of the connection and the O-Ring with engine oil.

DIAM. SERIES THREAD PITCH MOUNTING TIGHTENING

METRIC TORQUE Nm

- 1/8 GAS 20 ± 5%
6 M12 x 1.5 35 ± 5%
8 M14 x 1.5 35 ± 5%
10L/8P M16 x 1.5 40 ± 5%
12L/10P M18 x 1.5 45 ± 5%
12 M20 x 1.5 55 ± 5%
15L/14P M22 x 1.5 60 ± 5%
16P M24 x 1.5 70 ± 5%
18L M26 x 1.5 90 ± 5%
22L/20P M30 x 2 140 ± 5%
28L/25P M36 x 2 180 ± 5%
30P M42 x 2 240 ± 5%
35L M45 x 2 250 ± 5%
42L/38P M52 x 2 270 ± 5%

L = LIGHT
P = HEAVY
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Tightening torque for nuts of steel pipe connections (Nm)

Warning: before mounting check the following points:

- Check that the bushes of the connections to the hose show clear signs of the pressing. Otherwise discard
the hose.

- Remove the sealing plugs and ensure that the connections are clean.

- Lubricate the thread of the connection and the O-Ring with engine oil.

DIAM. SERIES THREAD PITCH MOUNTING TIGHTENING

METRIC TORQUE Nm

6 M12 x 1.5 40 ± 5%
8 M14 x 1.5 40 ± 5%
10L/8P M16 x 1.5 50 ± 5%
12L/10P M18 x 1.5 55 ± 5%
12 M20 x 1.5 65 ± 5%
15L/14P M22 x 1.5 70 ± 5%
16P M24 x 1.5 85 ± 5%
18L M26 x 1.5 110 ± 5%
22L/20P M30 x 2 170 ± 5%
28L/25P M36 x 2 215 ± 5%
30P M42 x 2 290 ± 5%
35L M45 x 2 300 ± 5%
42L/38P M52 x 2 325 ± 5%

L = LIGHT
P = HEAVY
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1.12.5 INSTALLATION OF CONNECTIONS ON STEEL PIPES

Description

The cutting ring has two sinking edges.

The installation instructions must be thoroughly followed. This is vitally important for the proper performance
of the connection.
For all systems with cutting ring - with one or two sinking edges - the advantages of a higher resistance can
be obtained only when the single mounting phases prescribed are followed to the letter.
For a good operation and a perfect sealing of the connection it is of fundamental importance, during the
tightening of the nut, not to rely on the tightening torque deriving from experience previously acquired, but
counting accurately the number of turns made and check the sinking after the pre-mounting.

Pipe

Nut

Cutting ring

Cutting edge
Thrust face Inner taper
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Body of adaptor
connection
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SS4-1-66

SUPERSTRUCTURE EX135W

Cut the pipe square (do not use roller type pipe
cutters).
Deburr accurately the inner and outer edges.

Lubricate accurately the treads and the cutting

ring.
Position the nut and the cutting ring on the pipe
as illustrated.
The larger diameter of the cutting ring must be
oriented toward the nut.

Push the pipe toward the body of the

connections until they contact the thrust face
inside the body of the connection, than strongly
tighten manually the nut, until it is felt that the
cutting ring is well positioned against the nut,
the pipe and the inner taper of the connection.

Mount the ring oriented in a correct manner.

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SS4-1-67

SUPERSTRUCTURE EX135W

Tighten manually the nut until a resistance is

felt, then tighten using a wrench. Turn the nut
(up to a pipe outer diameter of 18 mm) 1 1/2
turn. In this manner the cutting edge of the ring
enters the outer part of the pipe with the
required depth and lifts a well visible rim in
front of its cutting edge.

Loosen the nut and check that the pipe shows,

all around, a well etched rim. The rim must
cover 70 - 80% of the cutting ring front.

Reinstall the connection with a wrench until a

certain resistance is felt.
At this point, tighten further 1/2 turn.
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SS4-1-68

SUPERSTRUCTURE EX135W

NOTES:

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OPERATION PRINCIPLE HYP4-2-1
(O/P)
HYDRAULIC PUMPS EX165W

2. HYDRAULIC PUMPS

2.1 HYDRAULIC PUMPS

The machine is equipped with a group of pumps providing the main hydraulic power to all the systems and
with a gear double pump feeding the power system/brakes and steering.

2.1.1 PUMPS GROUP

The pumps group is mounted on the flywheel side of the engine and includes two pumps:
- main pump and secondary pump.
The two pumps, of a variable displacement swashplate axial piston type are tandem mounted.
The main pump is driven by the engine through an elastic joint; the secondary pump is driven by the through
shaft of the main pump.

1 - Secondary pump
2 - Main pump
3 - Flange
4 - Elastic joint
4
3

1
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OPERATION PRINCIPLE HYP4-2-2
(O/P)
HYDRAULIC PUMPS EX165W

2.2.2 GEAR DOUBLE PUMP

The gear double pump is mounted on the timing left side of the engine and includes two gear pumps mounted
axially.

1 - Power system/brakes pump

2 - Steering pump
2

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OPERATION PRINCIPLE HYP4-2-3
(O/P)
HYDRAULIC PUMPS EX165W

2.2 MAIN PUMP

2.2.1 CONSTRUCTION AND FUNCTION

The main pump (A11VO95 LRCS) is of a variable displacement swashplate axial piston type. The
displacement is proportionate to the revolution speed and the displacement. The position of the swashplate
allows a continuous variation of the displacement. The pump includes, essentially: a rotating group, included
inside the pump body; a valve plate; a regulator.

2.2.2 OPERATION OF THE MAIN PUMP

When the drive shaft rotates, oil is sucked by the movement of the pistons sliding along swashplate (5) through
the inlet ports of the valve plate.
When the pistons reach the bottom dead center (cylinder chamber totally filled with oil) the relevant cylinders
where they slide are communicating with the delivery port of the valve plate. While the shaft rotates, the oil
sucked by the retracting movement of the piston during the inlet phase, is pushed-out during the pushing
movement of the piston itself, in the compression phase. The alternating movement of the pistons, occurring
in a sequence for all 9 pistons due to the rotation of the shaft, causes the pressurised hydraulic oil to exit into
the feeding delivery piping. The delivery of the pump is proportionate to the r.p.m. and the inclination angle
of the swashplate where the pistons slide and it can be changed from a maximum to a minimum.
The speed of the pump depends upon the r.p.m of the engine to which it is mechanically connected.

2 1 5 4

1 - Rotor group
2 - Pump body
3 - Valve plate
4 - Regulator
5 - Swashplate
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3
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OPERATION PRINCIPLE HYP4-2-4
(O/P)
HYDRAULIC PUMPS EX165W

2.2.3 ROTOR GROUP

The rotor group includes 9 pistons sliding over the swashplate and kept in position by the retaining plate and
the cup springs (see detail X).
During the rotation of the drive shaft, the cylinder block, driven in a rotation, ensures that the pistons, sliding
over the swashplate, are alternatively moved, with a stroking travel inside the relevant cylinders.
The plate is at an angle with respect to the rotation shaft and its position can change as a function of the request
made by the operator and the power absorbed by the load. By changing the angle of the plate, the stroke of
the pistons with respect to the cylinders is changed, thus the displacement of the pump and the relevant
delivery is changed.
The valve plate is fixed and contacts the end of the cylinder block.

Rotor group

19 18 20 15 17 11 12 2 1

Detail X
5 6 7 10 4 13 16 14 21

1 - Cylinder 12 - Retaining ball

2 - Piston 13 - Washer, bearing
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3 - Cup spring 14 - Locking segment

4 - Swashplate 15 - Bearing
5 - Shaft 16 - Bearing
6 - Cover 17 - Retaining ring
7 - Retainer 18 - Retaining ring
8 - Washer 19 - Seal
9 - Spacer 20 - O-ring
10 - Retaining pin 21 - Screw
11 - Retaining plate 22 - Valve plate
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OPERATION PRINCIPLE HYP4-2-5
(O/P)
HYDRAULIC PUMPS EX165W

2.2.4 VALVE PLATE

The valve plate is mounted on the pump body and supports the regulator.

9 10 5 4 2 1 6

11

5 11

5
4
3 12
7
5 13

6 8

5 5 1 - Bush 8 - Orifice
2 - Valve plate 9 - Plug
3 - Bearing 10 - Plug
4 - Centering dowel 11 - Orifice
5 - Dowel 12 - O-ring
6 - Plug 13 - Bonded seal
7 - Plug

Inside, the seats for the swashplate control piston are made.
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OPERATION PRINCIPLE HYP4-2-6
(O/P)
HYDRAULIC PUMPS EX165W

2.2.5 REGULATOR

The regulator of the main pump includes:

1 - a constant power regulation circuit;
2 - a power control circuit related to the load requirement of the “cross sensing” swing pump;
3 - a control circuit monitoring the load applied to the “load sensing” pump.

3
X

1 - Power control valve

2 - Power control valve related to the load of the swing pump (cross sensing)
3 - Load sensing regulation valve
X - Input of the load sensing line 21599 60406991

Section B-B Section C-C

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OPERATION PRINCIPLE HYP4-2-7
(O/P)
HYDRAULIC PUMPS EX135W

Constant power regulation circuit

The constant power regulation circuit controls the volume of oil delivered by the pump related to the operating
pressure of the circuit and the power output, so that, for a given speed of the pump, the driving
.
power required from the engine is not exceeded, and the relation N = P Q = constant (where N = Diesel
Engine Power, P = Oil pressure, Q = delivery and K = coefficient). K

11

The pressure of the hydraulic oil of the feeding circuit, acting on a plunger inside counter-piston (3), actuates
a swinging arm (4).
On the other side of the swinging arm, a spring, adjustable from outside, is acting through a push-rod. When
turning screw (11) the power regulation is changed.
If the operating pressure of the feeding circuit exceeds the load setting of the spring, the power regulation valve
is commanded to open by the movement of the swinging arm. Thus, the feeding circuit line is connected with
the swashplate control piston (2) that, when moving, changes the position of the swashplate toward smaller
inclination angles. Consequently, the pump output decreases.

By reducing the oil flow, the new equilibrium value is re-established, so that P Q = constant is satisfied.
.

1 - Main pump 7
2 - Swashplate control piston
3 - Counter piston
4 - Swinging arm
5 - Power regulation valve 9
6 - Load sensing regulation valve
7 - Power regulation valve related to swing
4
pump load (cross sensing) 11
10
9 - Operation pressure reference line
10 - Plunger 5
1
11 - Adjusting screw
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3
2

F11112
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OPERATION PRINCIPLE HYP4-2-8
(O/P)
HYDRAULIC PUMPS EX165W

Power regulation circuit related to secondary pump load (cross sensing)

The power regulation circuit related to the secondary pump load is a system designed to maintain constant
the addition of all the powers absorbed by the main and secondary pump driven by the same shaft. The cross
sensing power regulation is actuated by the operating pressure of the secondary pump.
If the main pump is operating, and there is a load demand on the secondary pump, the cross sensing circuit
monitors the pressure variation coming from the circuit supplied by the secondary pump, altering the setting
of the power absorbed by the main pump in a proportional manner.

The intervention of the signal coming from the secondary pump applied to the cross sensing valve (7) acts
in contrast with the power regulation valve setting spring (11), changing the equilibrium point of the swinging
arm at a lower point.
In practice, each power demand on the secondary pump is compensated by deducting power from the main
pump.

Load sensing regulation circuit

The circuit includes the load sensing valve (6) located in the regulator and has the function of regulating the
output delivered by the main pump as a function of the variation required by the actuators, so that the
displacement of the main pump is best adapted in all the various operating conditions.
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OPERATION PRINCIPLE HYP4-2-9
(O/P)
HYDRAULIC PUMPS EX135W

The load sensing valve compares the pressure before and after restriction (8) generated by the position of
the spool in the control valve body and acts on the pump regulator so that the pressure drop (∆p) through the
restriction is maintained constant and the delivery of the pump is kept steady. (∆p = pump pressure - Actuator
pressure).
The pressure difference before and after the restriction is set at ∆p = 20 -+10 bar.
If the pressure difference ∆p tends to increase, the load sensing valve intervenes and allows the passage of
oil to the swashplate angle control piston to move it toward minimum displacement.
If the pressure difference ∆p, on the contrary, tends to diminish, the load sensing valve intervenes to command
the pump toward maximum displacement, until the position of the load sensing valve is balanced, so that the
pressure drop before and after the restriction generated by the spool is maintained at 20 bar.
When the main pump works on the power curve, the load sensing circuit is by-passed.

2.2.6 SPECIFICATIONS AND DATA

PUMP TYPE A11VO95 LRCS

Vmax = 95 cu cm
Displacement
Vmin = 0 cu cm

Max. delivery Qmax = 191 liter/min

at 2100 rpm

Max. power Nmax = 61 kW

at 2100 rpm

Weight (without fluid) P = 53 kg

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OPERATION PRINCIPLE HYP4-2-10
(O/P)

HYDRAULIC PUMPS EX135W

2.3 SECONDARY PUMP

2.3.1 CONSTRUCTION AND FUNCTION

The secondary pump (A10VO28 DFLR) is of a variable displacement swashplate axial piston type. The
displacement is proportionate to the revolution speed and the displacement. The position of the swashplate
allows a continuous variation of the displacement. The pump includes, essentially: a rotating group, included
inside the pump body; a valve plate; two regulators.

2.3.2 OPERATION OF THE SECONDARY PUMP

When the drive shaft rotates, oil is sucked by the movement of the pistons sliding along swashplate (3) through
the inlet ports of the valve plate.
When the pistons reach the bottom dead center (cylinder chamber totally filled with oil) the relevant cylinders
where they slide are communicating with the delivery port of the valve plate. While the shaft rotates, the oil
sucked by the retracting movement of the piston during the inlet phase, is pushed-out during the pushing
movement of the piston itself, in the compression phase. The alternating movement of the pistons, occurring
in a sequence for all 9 pistons due to the rotation of the shaft, causes the pressurised hydraulic oil to exit into
the feeding delivery piping. The delivery of the pump is proportionate to the r.p.m. and the inclination angle
of the swashplate where the pistons slide and it can be changed from a maximum to a minimum.
The speed of the pump depend upon the r.p.m. of the engine, to which it is mechanically connected, through
the main pump.

6
3 11

8 9

7
10 5

1 - Drive shaft
2 - Cylinder block
3 - Swashplate
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4 - Valve plate
5 - Angle control piston
6 - Counter piston
7 - Delivery regulator
8 - Power regulator
9 - Cut-off valve
10 - Pump body
11 - Valve plate
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OPERATION PRINCIPLE HYP4-2-11
(O/P)
HYDRAULIC PUMPS EX135W

2.3.3 ROTOR GROUP

The rotor group includes 9 pistons sliding over a swashplate kept in position by the retaining plate and pre-
load springs.
During the rotation of the drive shaft, the cylinder block, driven in a rotation, ensures that the pistons, sliding
over the swashplate, are alternatively moved, with a stroking travel inside the relevant cylinders.
The plate is at an angle with respect to the rotation shaft and its position can change as a function of the power
absorbed, through the regulator. By changing the angle of the plate, the stroke of the pistons with respect to
the cylinders is changed, thus the displacement of the pump and the relevant delivery is changed.
The valve plate is fixed and contacts the end of the cylinder block.

1 3 4 6 7 8

11

2 5 9 10

1 - Safety ring
2 - Seal
3 - Front roller bearing
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4 - Pistons
5 - Swashplate
6 - Spacer
7 - Rear roller bearing
8 - Ring
9 - Reference dowel
10 - Plug
11 - Inlet plate
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OPERATION PRINCIPLE HYP4-2-12
(O/P)

HYDRAULIC PUMPS EX135W

2.3.4 REGULATORS

The regulators of the secondary pump include: 2

- a constant power regulation circuit; 1
- a cut-off intervention circuit.

4 A

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1 - Displacement regulation valve

2 - Cut-off valve
3 - Power regulation valve
4 - Piston
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OPERATION PRINCIPLE HYP4-2-13
(O/P)
HYDRAULIC PUMPS EX135W

Constant power regulation circuit

The constant power regulation circuit controls the volume of oil delivered by the pump related to the operating
pressure of the circuit and the power output, so that, for a given speed of the pump, the driving
.
power required from the engine is not exceeded, and the relation N = P Q = constant (where N = Diesel
Engine Power, P = Oil pressure, Q = delivery and K = coefficient). K
The power regulation circuit includes a displacement regulation valve (1) and power regulation valve (3).
The combined operation between these two valves, allows the variation of the displacement of the pump as
a function of the load: in essence, the regulation of power.
Plunger (4) of the displacement regulator is connected to the pilot line and it is subject to pressure on both
sides (A and B).
Side (B) is pre-loaded by a regulation spring. As far as the pressure in (A) is equal to the pressure in (B) the
plunger is kept in rest position. Under these conditions, the secondary pump provides maximum delivery.
When the operating pressure exceeds the value for the beginning of the intervention of the power regulator,
the power regulation valve (3) opens, discharging side (B) of the plunger, thus creating a pressure differential
between (A and B).
This differential modifies the position of the plunger and the signal in the line is sent to the swashplate angle
control piston, thus modifying the displacement, until a new equilibrium point is found.

P2

B
X

Ø 0.8

(1)
(8)
CUT-OFF: 310 bar

(2)

(4) (3)

1 - Displacement regula-
tion valve
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2 - Cut-off valve
(5) 3 - Angle control piston
4 - Power regulation valve
Q max Q min. 5 - Counter piston
S L1 L 6 - To main pump
CROSS SENSING 7 - Cross sensing line
(6)
(7) 8 - Pilot line
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OPERATION PRINCIPLE HYP4-2-14
(O/P)

HYDRAULIC PUMPS EX135W

Cut-off intervention circuit

Once a value of 310 bar is reached on the operation line, the plunger of the cut-off valve (2) overcomes the
load of the spring, connecting the pilot line (8) with the angle control piston. Under these conditions, the pump
provides a displacement capable of ensuring a steady pressure and compensating eventual leakages in the
system.
The cut-off valve inhibits every other function of the regulators.

2.3.5 SPECIFICATIONS AND DATA

PUMP TYPE A10VO28 DFLR

Displacement Vgmax = 28 cu cm

Max. delivery Qgmax = 58 liter/min

at 2100 rpm

Max. power Pomax = 16 kW

at 2100 rpm

Weight (without fluid) P = 15 kg

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OPERATION PRINCIPLE HYP4-2-15
(O/P)
HYDRAULIC PUMPS EX135W

2.4 GEAR DOUBLE PUMP

2.4.1 GENERALITIES

The gear double pump, of a fixed displacement type, includes the power system/brakes pump (1) and steering
pump (2), and is mounted on the front left side of the engine.
The power system /brakes pump (1) sucks the oil through a suction filter from the hydraulic reservoir and sends
it, after going through the power system filter, to the brake valve and then, after charging the brake system
accumulators, sends it to the priority valve feeding the controls.
Steering pump (2) sucks the oil through the suction filter from the hydraulic reservoir and sends it directly to
the inlet of the power steering valve.

Operation

A gear is driven by the engine through the transmission and drives a second gear.
As a consequence of the rotation in an opposite direction of the gears, the vanes between the teeth become
free. The depression created and the pressure acting on the surface of the fluid in the reservoir, push the oil
from the reservoir to the pump.

2.4.2 SPECIFICATIONS AND DATA

Power system/brakes pump:

q = 20 cu cm/turn
Q = 38 l/min (at 2100 rpm)

Steering pump:
q = 20 cu cm/turn
Q = 38 l/min (at 2100 rpm)
3

2
1

DELIVERY
19400 60406991

1 - Power system/brakes pump

2 - Steering pump
F11116
3 - Power take-off
SUCTION
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OPERATION PRINCIPLE HYP4-2-16
(O/P)

HYDRAULIC PUMPS EX135W

NOTES:

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DISASSEMBLY AND ASSEMBLY HYP4-2-1
(D/A)
HYDRAULIC PUMPS EX135W

2.1 MAIN PUMP

2.1.1 GENERAL REPAIR INSTRUCTION

Note - Observe the following notices when carrying out repair work on hydraulic components.

• Close all ports of the hydraulic components.

• Replace all removed seals.

• Check all seals and sliding surfaces for wear.

ATTENTION - Rework of sealing area f. ex.
with abrasive paper, can damage surface.

• Fill up main pump with hydraulic oil before start-

up.
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DISASSEMBLY AND ASSEMBLY HYP4-2-2
(D/A)
HYDRAULIC PUMPS EX135W

CAUTION - The approximate weight of the main B

pump (without oil) is: 53 kg.

2.1.2 DISASSEMBLY

A
1 Unscrew (A), remove pump support (B) and
remove O-ring (C).
C

2 Unscrew the fixing screws and remove regulator

housing (D), be sure that the sealing surface is D
not damaged.

Note - Do not change the set of adjusting screws.

E - Power control;
E
F - Cross-sensing valve;
G - Load-sensing valve.

3 Remove O-ring (H) measuring piston (I) with bush

and spring.
H
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I
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DISASSEMBLY AND ASSEMBLY HYP4-2-3
(D/A)
HYDRAULIC PUMPS EX135W

4 Mark position of the connection plate. Loosen

connection screws (L) of fixing plate.

L L

5 Remove port plate with control plate.

N M

(M) Feed back piston;

(N) Control piston for swivel plate.

6 Mark position of control plate (23), then remove

it.
23

7 Loosen the screws (20) fixing retaining segments

(19).
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20
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DISASSEMBLY AND ASSEMBLY HYP4-2-4
(D/A)
HYDRAULIC PUMPS EX135W

8 Remove the retaining segments (19).

19

9 Remove O-ring (O).

O

10 Remove cylinder (22) with pistons (18), from

pump housing (7).
22

18

11 After noting down adjustment dimension of

screws (8) Q.min and Q.max, remove screws.

12 Remove plugs (13) then remove joint pin (14) for

swivel cradle.
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14

14
13
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DISASSEMBLY AND ASSEMBLY HYP4-2-5
(D/A)
HYDRAULIC PUMPS EX135W

13 Withdraw the spring ring (1), then remove cover

ring (2), seal ring (3) and the O-ring (4).
4
3
2
1

14 With plastic hammer press out drive shaft (5) with

the bearing (6).

15 Remove swivel cradle (11) with bearing (10) as

well as bearing cup (9).
11

10
10

INSPECTION
S
R
Q
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P
16 Check:
• Spline (P);
• Contact area shaft seal (Q);
• Spline (R);
• Bearing seat (S).
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DISASSEMBLY AND ASSEMBLY HYP4-2-6
(D/A)
HYDRAULIC PUMPS EX135W

17 Check:
• Bearing (10);
• Bearing cup set (9).
10 9

18 Check: T
• Contact seal area (T);
• Centring socket for regulator (U).

19 Check:
• Contact sliding area of bearings as shown.

20 Check:
15
• Retaining ball (15);
• Retaining plate (16).
16

21 Check:
• Fixing segments (19). 19
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16
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DISASSEMBLY AND ASSEMBLY HYP4-2-7
(D/A)
HYDRAULIC PUMPS EX135W

22 Check:
• Slipperpads (V); V
• Axial backslash of pistons (18).

18

23 Check:
• Cylinder boring (Z) of pistons (18);
• Spline of cylinder (22).
Z

22

24 Check:
• Contact area of cylinder (22) and contact area
of control plate (23). 23

22

25 Check:
• fixing segments.

26 Check:
• pistons.
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DISASSEMBLY AND ASSEMBLY HYP4-2-8
(D/A)
HYDRAULIC PUMPS EX135W

27 Check:
• positioning piston (1);
• boring - control bush (2).

28 Check:
• Contact area of control plate (23) and port plate.

2.1.3 ASSEMBLY

1 Insert bearing cups (9). 9

2 Clean threaded boring, as shown.

3 Install bearing (10) with retainer (12) on swivel ∗

cradle (11), holding together in position with 11
suitable mounting device (*) or (**).
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12
10
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DISASSEMBLY AND ASSEMBLY HYP4-2-9
(D/A)
HYDRAULIC PUMPS EX135W

(*) Bend clamp

(**) Grease ∗

∗∗

4 Install the assembly consisting of swivel cradle

(11) with bearings (10) into bearing cups (9) in
the related seats. Position correctly the retainer
(12) then remove (if used) the mounting device
(*).

Note - Verify the correct installation of assembly

on its seat.

5 Remove auxiliary devices.

Attention! Check bearing seats.

6 Install joint pins (14) then screw the plugs (13).

14

7 Fit swivel cradle (11) with two threaded pin (***) in

zero position.
∗∗∗
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11
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DISASSEMBLY AND ASSEMBLY HYP4-2-10
(D/A)
HYDRAULIC PUMPS EX135W

8 Install drive shaft (5) complete of bearing (6) on the

housing pump (7).

9 Mount O-ring (4) in the seat.

10 By means of a mounting device, insert the seal 2

ring (3) in the cover ring (2). 3
▲ 5
Note - If the shaft results with wear in the seal
area, it needs to install a shim s before seal ring
(3) to move the seal work area, as shown.

Then install the assembly on the shaft (5).

11 Install spring ring (1) on the seat of housing pump

(7).

12 Mount shim, springs (21) and retaining ball (15).

15
Observe correct mounting position, as shown.
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21
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DISASSEMBLY AND ASSEMBLY HYP4-2-11
(D/A)
HYDRAULIC PUMPS EX135W

13 Place retaining plate (16) with piston (18) into

cylinder (22).
16

18

22

14 Holding assembled pistons with the aid of an O-

ring as shown, install the assembly in the pump.

15 Insert fixing segments (19).

19

16 Install screws with Loctite. Tight screws with torque

value.

17 Install the complete control piston for swivel plate

(N) on its seat.
N
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DISASSEMBLY AND ASSEMBLY HYP4-2-12
(D/A)
HYDRAULIC PUMPS EX135W

18 Install the complete control piston for swivel plate

(N) on its seat.

19 Install control plate (23) as shown, in according

with the direction of rotation.

20 Fix port plate, assembly with screws (L). Tight

screws with torque value.

L L

21 Remove threaded pins (***) priorly installed.

8 8
Install adjustment screws Q.min and Q.max (8).
Reposition the adjustment screws at the
measurement priorly noted.

∗∗∗ ∗∗∗

22 Install measuring piston (I) with bush and spring

with O-ring (H).

H
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I
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DISASSEMBLY AND ASSEMBLY HYP4-2-13
(D/A)
HYDRAULIC PUMPS EX135W

23 Place regulator (D).

D

24 Install O-rings (C), support pump (B) and tight B

screws (A).

11
9 10
8

6
5 12
4
2 3
1 17 13

14
15
16

23
21 22

20
19
18
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1 Spring ring - 2 Cover - 3 Seal ring - 4 O-ring - 5 Shaft - 6 Bearing - 7 Pump housing - 8 Flow adjustment screw -
9 Bearing cup - 10 Bearing - 11 Swivel plate - 12 Retainer - 13 Plug - 14 Joint pin - 15 Retaining ball - 16 Retaining
plate - 17 Spring ring - 18 Piston - 19 Fixing segment - 20 Screw - 21 Springs - 22 Cylinder - 23 Control plate.
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DISASSEMBLY AND ASSEMBLY HYP4-2-14
(D/A)
HYDRAULIC PUMPS EX135W

2.1.4 TIGHTENING TORQUES

THREAD BOLT HARDNESS GRADE

8.8 10.9 12.9

Nm/ftlb
M3 1.08/0.78 1.6/1.15 1.9/1.37
M4 2.84/2.05 4.0/2.89 4.8/3.47
M5 5.90/4.26 8.3/6.00 9.8/7.09
M6 9.80/7.09 14/10.1 17/12.2
M8 24/17.3 34/24.5 40/28.9
M10 48/34.6 68/49.1 81/58.5
M12 84/60.6 118/85.2 142/102.5
M14 132/95.3 186/134.3 226/163.2
M16 206/148.7 289/208.6 348/251.3
M18 284/205.0 397/286.6 476/343.7
M20 402/290.2 569/410.8 677/488.8

THREAD Nm ftlb

M12 x 1.5 20 14.5

M22 x 1.5 60 43.3
M26 x 1.5 70 50.6
M33 x 2 120 86.8

THREAD Nm ftlb

M12 x 1.5 30 21.7

M14 x 1.5 40 28.9
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DISASSEMBLY AND ASSEMBLY HYP4-2-15
(D/A)
HYDRAULIC PUMPS EX135W

2.2 SECONDARY PUMP

2.2.1 GENERAL REPAIR INSTRUCTION

Note - Observe the following notices when carrying out repair work at hydraulic components.

• Sealing set complelely (sealing sets are based on the

type of the pump, picture shows for example A 10 VSO
DFR, without pilot valve seals). Sealing material: drive
shaft sealing ring FPM, others NBR.

F6895

• Same like previous picture. Only difference: all material

FKM.

F6896

• Drive shaft: spare part supply offers you the following

drive shaft types:
ISO - key design, SAE - key design, SAE - splined
design.

F6897

• Contents of kit "bearing set / miscellaneous parts": 2

tapered roller bearings, 2 bearings shells, adjustment
shim, spacer shim, plugs cylindric pin to fix the valve
plate.
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F6898
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DISASSEMBLY AND ASSEMBLY HYP4-2-16
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HYDRAULIC PUMPS EX135W

• The rotary group is complete with its cylinder with

mounted pressure - pins for cw or ccw rotating
units (pls order your direction of rotation).

F6899

• Swash plates are available for cw or ccw rotating

units in the serial design or for horse power
controlled pumps by our spare part service. (Order
your direction of rotation).

F6900
• Pcture left shows the control device parts without
the stopper parts. Order with stopper parts if
necessary (see RE 90 124).

F6901
• Order a checked and preadjusted pilot valve to
control the pump for pressure compensator ad
flow control. Easy handling is possible to convert
the design of the pilot valve.

F6902

• Pilot valve design 18 to 100:

Adapter without orifice of the DFR - pilot valve.
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F6903
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DISASSEMBLY AND ASSEMBLY HYP4-2-17
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HYDRAULIC PUMPS EX135W

• Picture left shows the pressure compensator

disassembled.
Mount on top of the pressure compensator housing
the valve housing for the flow control.

F6904

Pump unit

1-2 This discription showes how to change the drive

shaft sealing ring but it isn't the way of serial
assembly. The sealing ring is assembled together
with the taper roller bearing from inside the pump
housing normally to get a secure sealing condition.
If you decide to repair the pump in the shown way
be very careful while handling so that the drive
shaft wouldn't be damaged during disassembly of
the shaft sealing ring.

3 Disassemble of the key.

4 Remove the retaining ring.

F2541

5 Grind screwdriver to disassemble the shaft sealing

ring carefully. Pay attention: Damages of the drive
shaft indicate leakage.
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DISASSEMBLY AND ASSEMBLY HYP4-2-18
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HYDRAULIC PUMPS EX135W

6 Change the shaft seal and check the contact

surfaces (drive shaft and housing), grease sealing
ring before mounting.

F2539

7 Use installation tool for the sealing ring.

F6906

8 Use a suitable pipe or use the control piston of a

bigger pump size to mount the shaft seal ring via
the installation tool, bout don't push it too deap. If
the shaft seal ring touches the bearing ring you will
damage the seal ring.

F2540

9 Assemble the retaining ring.

F2541

10 Assemble the rataining ring. Assemble the key

next by using a plastic hammer. This handling isn't
shown in pictures.
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F6907
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DISASSEMBLY AND ASSEMBLY HYP4-2-19
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HYDRAULIC PUMPS EX135W

11 Loosen the fixing screws and disassembly the

regulator.

F2542

12 Mark the position of the port plate to pump housing

and loosen the socket screws of the port plate.

F2543

13 Remove the port plate together with the valve plate

and control device parts.
Note - Hold the valve plate so that the plate can
not fall down.

F2544

14 Disassemble the taper roller bearing and

adjustment shim.

F2545

15 Disassemble the rotary group.

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F2546
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DISASSEMBLY AND ASSEMBLY HYP4-2-20
(D/A)
HYDRAULIC PUMPS EX135W

16 Remove the O-ring.

F2547

17 Disassemble bearing shells.

F2548

18 Use puller bearing to remove outer bearing race

of front bearing.

F2549

19 Remove the control plate.

F2550

20 Use bearing puller to remove outer bearing race

of rear bearing.
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F2551
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DISASSEMBLY AND ASSEMBLY HYP4-2-21
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HYDRAULIC PUMPS EX135W

21 Remove the O-rings.

F2552

22 Disassemble the head nut of threaded pin.

F2553

23 Disassemble the hexagon fixing nut and the

threaded pin.

F2554

24 Disassemble the swash control piston.

F2555

25 Disassemble the feedback piston.

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F2556
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DISASSEMBLY AND ASSEMBLY HYP4-2-22
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HYDRAULIC PUMPS EX135W

26 Pull out the drive shaft.

F2557

27 Remove the pistons and the retaining plate.

F2558

28 Remove the retaining ball.

F2559

29 Compress the center spring withthe help of a bolt

complete with washer.

F2560

30 Disassemble the retaining ring.

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F2561
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DISASSEMBLY AND ASSEMBLY HYP4-2-23
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HYDRAULIC PUMPS EX135W

31 Remaining parts of the cylinder: pins, cylinder,

shim, spring and reaining ring.

F6908

32 Assemble the pump in reverse order and note the

following steps.

33 Taper roller bearing in the cast iron pump housing

must have a initial tension with 0 ÷ 0,05 mm.

F6909

34-35 Port plate (direction of rotation clockwise): Both

piston guides are glued with Loctite.

- Correct position of the valve plate (clockwise 4°):

In case of series 31 the valve plate only can be
installed into the correct position.
- Grease O-rings prior assembly.

F6910
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DISASSEMBLY AND ASSEMBLY HYP4-2-24
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HYDRAULIC PUMPS EX135W

36 Port plate (direction of rotation anti-clockwise):

Both piston guides are glued with Loctite.

- Correct position of the valve plate (clockwise

4°): in case of series 31 the valve plate only can
be installed into the correct position.
- Grease O-rings prior assembly.

F6911

38 Correct position of cradle (lubrication bore relief

on the high pressure side), use cradle for clockwise
rotation, if counter clockwise use cradle for counter
clockwise rotation (two different sub-assemblies)

F6912

39 If it possible to lap the cradle (sliding area of the

piston shoes) it can be possible to use the cradle
again. Notice: It isn't allowed to press out the
piston connection parts out of the cradle (scorings
while fitting!)

F6913

40 Connection surfaces between valve plate and

cylinder: if lapping is possible use parts again, but
after lapping procedure use a lapping paper No.
1000 to plan the cylinder and valve plate.

F6914
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DISASSEMBLY AND ASSEMBLY HYP4-2-25
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HYDRAULIC PUMPS EX135W

41 Check running conditions of the control piston.

F6916

42 Check running conditions of the opposite piston.

F6915
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DISASSEMBLY AND ASSEMBLY HYP4-2-26
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HYDRAULIC PUMPS EX135W

Regulator

1 Loosen socket screws. Remove the regulator and

place it on work bench.

F2563

2 Remove the O-ring.

F2564

3 Close the port (T), blow out with dry air pressure
at port (A) to clean the regulator.
ATTENTION - Be care that there is no skin
connection during blowing. Look how the orifice
comes out before blowing.

F2565

4 Remove the hexagon nut, disassemble first the

power control, afterwards the flow control.

F2566

5 Loosen the lock nut and unscrew threaded pin.

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F2567
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DISASSEMBLY AND ASSEMBLY HYP4-2-27
(D/A)
HYDRAULIC PUMPS EX135W

6 Disassemble the plug.

F2568

7 Remove the spring collar.

F2569

8 Remove the spring.

F2570

9 Remove the spring cup.

F2571

10 Disassembly the plug.

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F2572
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DISASSEMBLY AND ASSEMBLY HYP4-2-28
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HYDRAULIC PUMPS EX135W

11 Be careful while disassembling the piston.

F6917

12 Disassemble the plug or orifice (spring area of

flow control).

F6918

13 Clean housing and parts with clean fluid and dry

with are carefully.

F6919

14 Assemble pilot valve in reverse order and note

the following (60to 63).

15 Check the opening of the orifice.

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F6920
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DISASSEMBLY AND ASSEMBLY HYP4-2-29
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HYDRAULIC PUMPS EX135W

16 Be careful when loctiting the orifice.

17 Check the movement of the pilot valve spols, and

drillings should not be damaged.

F6922

18 Adjustments of the bypass orifice:

• open position of the orifice: like shown on the
picture
• turn the orifice 90° to close it.

F6923

19 For adjustment of the pilot valve see set up

instructions.

F6924
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DISASSEMBLY AND ASSEMBLY HYP4-2-30
(D/A)
HYDRAULIC PUMPS EX135W

20 Mechanical flow limiter (both stopper max. and

min. flow).

Size 45

3.23

Differential volume (cm3) if you are rotating the

threaded pin - each rotation.

mechanical stopper min. flow adjustable

Taper roller bearing initial tension 0÷0,05

Note for size 18 and 28:

The small pump sizes have to be measured by

using a special shim (Pos. 12) with its tolerance of X
1,5 ± 0,01 see detail X. This shim will be
disassembled after the measurement.
Measurement, thickness of the special shim and
necessary pretention all together makes the
thickness of the adjustment shim (Pos. 12). Pos. 12

Cast iron housing must have initial tension of the

bearings: 0 ÷ 0,05 mm, grind Pos. 12 if necessary. special shim

21 DR: When pressure line is closed adjust the

pressure of the controller (if it's DFR design then
open the adjustable orifice and increase force of
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the FR - spring).

F6927
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DISASSEMBLY AND ASSEMBLY HYP4-2-31
(D/A)
HYDRAULIC PUMPS EX135W

22 FR: If swivel angle is in the mid position adjust

differential pressure 14 bar (adjustable orifice in
the system pressure line is partly closed).

F6928

23 Mechanical flow limiter: While screwing in the

threaded pin you will be able to reduce the flow
from Vg max to 35% reduction of Vgmax dependent
on the size of the pump (If you need more
reduction of the flow, don't mount the fixing
hexagon nut. Note: to adjust the threaded pin
without the fixing hexagon nut do it by the existence
of the working pressure).

F6929

24 Loctite used:
break - off plugs Nr. 601
normally Nr. 242

Tightening torques

Bolt hardness grade: 8.8; 10.9; 12.9

M4 M5 M6 M8 M10 M1 2 M1 4 M16 M18 M20 M24 M30

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8.8 2.3 5.0 8.5 21 41 72 115 176 24 0 35 0 600 1220

Ma 10.9 3.2 7.2 12 29 58 100 16 5 25 0 350 49 0 840 1670

12.9 4.1 8.5 14.5 35 70 12 1 195 300 41 0 59 0 990 2000

F7069i
Ma (Nm) = max. tightening torques (screws lubricated µ = 0.125)
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DISASSEMBLY AND ASSEMBLY HYP4-2-32
(D/A)
HYDRAULIC PUMPS EX135W

2.3 GEAR DOUBLE PUMP

CAUTION - The weight of the gear double pump is about 5.2 kg.

2.3.1 DISASSEMBLY

Note - Prior to proceeding with the disassembly operation:

• clean accurately the outer surfaces of the gear double pump;
• each reference marks on the contact faces, on cover (1), bodies (2 and 7), flange (10) and suction and
delivery ports.

1 Block flange (10) of the pump in a vice, with cover (1) upward.

2 Loosen and remove screws (24).

3 Remove cover (1) and the relevant O-ring (16).

4 Remove the body of power system/brakes pump (2) complete with gears (13 and 14) and bushes (3 and
4).

5 Pull-out gears (13 and 14) then recover bushes (3 and 4) from power system/brakes valve (2).

6 Remove the two back-up rings (19) and seals (18) from bushes (3 and 4).

7 Remove the two intermediate plates (5 and 6) then separate them and pull-out joint (15) and O-rings (16).

8 Remove the body of steering pump (7) complete with gears (11 and 12) and bushes (8 and 9).

9 Pull-out gears (11 and 12) then recover bushes (8 and 9) from the power steering body (7).

10 Remove back-up rings (19) and seals (18) from bushes (8 and 9).

11 Remove O-ring (16) from flange (10).

12 Using the appropriate pliers, remove snap ring (21), then remove the two seals (17) together with
reinforcement ring (20).
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DISASSEMBLY AND ASSEMBLY HYP4-2-33
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HYDRAULIC PUMPS EX135W

2.3.2 INSPECTION

Check that the components removed are free from fouling and do not show signs of discoloration, then clean
them with diesel fuel.

Note - Do not clean rubber made components with diesel fuel.

Pump body

In order to work in an efficient manner, the pump is designed so that the relevant gears turn with the tip of the
teeth very near the body. Thus, a used pump shows a contact trace near the suction port. The nominal length
of the contact trace is about 1/3 of the inner circumference of the body.
In case the trace is longer than half the circumference, this could be an indication of the wear of one bush or
one gear shaft.

ACCEPTABLE TRACE

NON ACCEPTABLE TRACE

Bush

A bush can be considered in good conditions, when the inner contact face is not rough and the contact faces
of the gears are shining without signs of important scoring.

Replace the bush when the following conditions are found:

• when the roughness of the inner surface is such to be felt by a finger nail;
• when the contact results extended to the entire sliding surface;
• when the roughness of the side face is such to be felt by a finger nail;
• when it is evident that foreign materials have entered the bushing mating faces, the gears and the pump body.

HUB FACE
CONTACT SURFACE
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SUCTION SIDE DELIVERY SIDE

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DISASSEMBLY AND ASSEMBLY HYP4-2-34
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HYDRAULIC PUMPS EX135W

Gear

Replace the gear when the following conditions are found:

when the sides of the gears are chipped;
when the surface of the gears is cracked or abnormally worn on one side only.

Note - If the surface is rough or discoloured, also the bush and the pump body could result in bad conditions,
thus it is necessary to check them.

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DISASSEMBLY AND ASSEMBLY HYP4-2-35
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HYDRAULIC PUMPS EX135W

2.3.3 ASSEMBLY

Note - Prior to proceeding with the assembly operations:

• clean all components, then lubricate the inner ones with hydraulic fluid;
• install the O-rings only after greasing appropriately the relevant seats.

1 Install bush (8) in the steering pump body (7), ensuring that the direction of the suction and delivery are
correct.

2 Insert gears (11 and 12) and close the gear group by mounting bush (9).

3 Insert flange (10) paying special attention to seals (17).

4 Install intermediate plate (6), then insert joint (15) in the relevant seat, ensuring that it engages perfectly
with gear (12).

5 Install intermediate plate (5) after positioning dowels (22).

6 Install bush (4) in the power system/brakes valve body (2), ensuring that the directions of the suction and
delivery are correct.

7 Mount the power system/brakes pump body (2) on intermediate plate (5).

8 Insert gears (13 and 14) and close the gear group by mounting bush (3).

9 Insert dowels (22), then install cover (1).

10 Mount the four screws (24) and the relevant washers (23) tightening them to the prescribed torque.
Tightening torque: 4 daNm.

Note - Prior to the installation on the machine, check, by rotating manually, that the pump is not seized.
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DISASSEMBLY AND ASSEMBLY HYP4-2-36
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HYDRAULIC PUMPS EX135W

1 Cover - 2 Pump body - 3 Bush - 4 Bush - 5 Intermediate plate - 6 Intermediate plate - 7 Pump body - 8 Bush
- 9 Bush - 10 Flange - 11 Gear - 12 Gear - 13 Gear - 14 Gear - 15 Joint - 16 O-ring - 17 Seal - 18 Seal - 19
Back -up ring - 20 Reinforcement ring - 21 Snap ring - 22 Dowel - 23 Washer - 24 Screw.
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OPERATION PRINCIPLE CV4-3-1
(O/P)
CONTROL VALVE EX135W

3. CONTROL VALVE

3.1 CONTROL VALVE

3.1.1 OUTLINE

The control valve allows all the movements of the machine. It consists of three bodies: right, central and left
(see Fig. 1 and 2).
• The right body (M7), center closed type, is fed by main pump and includes the five directional control valves
(spool axis) that are used for movements control of arm, boom, travel, positioning and bucket.
• The unloading valve is a block fastened to control valve right body.
• The central body consists of a manifold plate on which are installed the check valves for return oil circuit
control and flow limiter valve of Load Sensing circuit.
• The left body (M8), center opened type, is fed by secondary pump and includes two directional control
valves that are used for movements control of upperstructure swing and blade/stabilizers.
The bodies of control valve are mechanical tied by means of bolts, while the hydraulic connections are
obtained by means of inner conduits. The seals are assured by O-rings.

Fig. 1 - Control valve

4
Control valve front view
3
1
2

2
1
3
4
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1 - Right body (M7)

2 - UNLOADING valve
3 - Central body
F3217
4 - Left body (M8) Control valve rear view
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OPERATION PRINCIPLE CV4-3-2
(O/P)
CONTROL VALVE EX135W

Fig. 2 - Control valve hydraulic diagram

Pressure relief valve

From secondary
pump

Control valve
Swing 7
left body

6 Compensated flow
Blade/lateral
regulating valve for
stabilizer
LS signal

To hydraulic
To oil radiator oil tank Control valve
Pressure relief valve central body
(cut off)
Main pressure relief valve

Bucket From main

5
pump

Positioning 4

Travel Control valve

right body
(five spool)

Boom
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Arm

F6992
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OPERATION PRINCIPLE CV4-3-3
(O/P)
CONTROL VALVE EX135W

3.1.2 CONTROL VALVE RIGHT BODY

In the right body (M7) are installed (see Fig. 3):

- Five directional control valves:
1 Arm - 2 Boom - 3 Travel - 4 Positioning - 5 Bucket;
- Main pressure relief valve
- Pressure cut off valve
Each directional control valve consists of a spool, two ports A and B connected to the user, and two ports a
and b, connected to pilot control valves.
Beside this, and depending on the user that should be controlled, the directional control valves can be
equipped with pressure relief and anticavitation valves, or only with anticavitation valves.
On the pilot pressure ports, throttle valves with free flow check valve are arranged in such a way that the pilot
pressure input is unrestricted, meanwhile the pilot return is throttled in a orifice so that a damping action is
obtained.

ATTENTION
Each individual directional control valve is matched to the requirements of user. Therefore the spools
of directional control valves are not interchangeable to each other.

The function of each directional control valve is to transfer the hydraulic oil flow demand to the users as
required by the operator moving the pilot control valves.

Control valve right body function

• Load Sensing circuit

The right body of control valve, together with the main pump, operates so as to guarantee an hydraulic supply
distribution in an independent way of load applied, if it remain out of power controlling.
The circuit, called Load Sensing, works so that only the required flow oil is generated by the main pump.

As long as no pilot control valves are operated and no flow is required from user (all control spools are in neutral
position), the Load Sensing line, and therefore X port of pump governor, has no pressure (see Fig. 4).
The spool of Load Sensing valve of main pump governor is maintained in rest position by the setting spring
action.

In these conditions the main pump supplies only as much oil, as it is required to compensate the system
leakage; the pressure of pump supply line (stand-by pressure) is about 30 to 34 bar (this value can be
measured at M port of main pump).

When a spool control valve (2) is operated by a pilot valve device, an hydraulic oil route from the pump to the
user is opened.
The opening cross section, that occurs with the movement of directional control valve spool, operates
practically like a gauging orifice.
Any oil flow change (movement speed of user) controlled by the operator, has an effect on the pump flow
through the Load Sensing signal.

When only one spool of directional control valve (2) is operated, the pump pressure is provide to the user, and
by means of the Load Sensing line, is applied to the spring side spool of Load Sensing valve (1.1) of pump
governor.
The position of pump swivel plate will change to increase the flow in according to the demand.
When the pump supply pressure exceeds the load pressure, the user begins to move and the incoming flow
21599 60406991

generates a pressure drop (∆p2) through the orifice of control spool.

When this pressure drop (∆p2) corresponds to the spring setting load of Load Sensing valve of governor, a
balance is established (∆p = 21 bar).
The pump reacts to each control spool movement because its governor has the function to maintain a pressure
drop constant (∆p2) to any change of gauging orifice (control spool).
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OPERATION PRINCIPLE CV4-3-4
(O/P)
CONTROL VALVE EX135W

Fig. 3 - Control valve right body (M7)

19
1
3
4

3
2

3 16
4 5
3

17
6

7
8
12/13

9
10

12
18
18
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F6877
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OPERATION PRINCIPLE CV4-3-5
(O/P)
CONTROL VALVE EX135W

16 17
2 14
3

10

3
15 19
4 9
5

15
4 8
12

13
15 5
3

3
12 7
5
15

3 6
5
1
3

F6993

15

Fig. 3

1 - Control valve right body 12 - Throttle valve one way (Ø 1.2)

2 - Main pressure relief valve 13 - Throttle valve one way (Ø 0.8)
3 - Pressure relief and anticavitation valve 14 - Throttle valve two way (Ø 1.2 and Ø 0.6)
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4 - Anticavitation and check valve 15 - Check valve

5 - Pressure compensator
6 - Arm control spool
7 - Boom control spool
8 - Travel control spool
9 - Positioning control spool
10 - Bucket control spool
16 - Pressure cut off valve
17 - Orifice (Ø 1.6)
18 - Spool stroke end adjusting screw
19 - Unloading valve
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OPERATION PRINCIPLE CV4-3-6
(O/P)
CONTROL VALVE EX135W

• Load compensation circuit

In case several users are operated at the same time, the pressure of highest load always is directed into the
Load Sensing line and forwarded to the pump Load Sensing governor (see Fig. 4).
All the pressure compensators (3) are connected among them by means of Load Sensing line.
The pressure compensator related to the highest load user is fully opened.
The flow to the other lower load users is controlled by the pressure compensator on which this highest load
pressure works, with the result to equalise the difference between the own user pressure and pressure of
highest load.
By that the same conditions on all the gauging orifice of operated users are obtained, that is:
a) the pump pressure before the gauging orifices.
b) a pressure behind the gauging orifices which will assume a value equal to the pressure before the gauging
orifice minus the pressure drop set on Load Sensing controller of pump (1.1).
In this way the movement is guaranteed at the same time to all the users, apart from the applied load to each
user.

• Unsaturated circuit

If now the required oil flow of operated users becomes higher than the maximum pump flow, the pressure drop
on the gauging orifice of spool axis decreases under the value of pressure drop of Load Sensing controller
(1.1).
In these conditions the Load Sensing controller is out of function and the pump is thereby swivelled to the
maximum and follows the constant power controller only.
The distribution of the oil flow to the users is therefore proportional and corresponds only to the opening of
gauging orifice and is further on load independent (always if it remains out of power controlling).
The pressure drop over the gauging orifice is equal to:

∆p 2.1 = ∆p 2.2 = ∆p 2.3 < ∆p 1.1

In these conditions all the users are operating. The pump flow is distributed to the users proportionally to the
cross opening section of control spools, assuring the movement at the same time. This property remains
established until a pressure drop of ∆p 2 = 3 bar.

Fig. 4 - Schematic diagram of Load Sensing Circuit

Con tutti i cassetti funzionanti

21599 60406991

1 Main pump - 1.1 Load Sensing controller - 1.2 Constant Power control valve - 2 Control valves spool axis for
direction and speed control equivalent to a gauging orifice - 3 Pressure compensator with integrated Load Sensing
pressure comparison - 4 Load holding check valves - 5 Flow limiter valve - 6 Pressure cut off valve - 7 Load Sensing
line.
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OPERATION PRINCIPLE CV4-3-7
(O/P)
CONTROL VALVE EX135W

Directional control valve description

• Construction

Each directional control valve (see Fig. 5) consists of housing (3), the control spool (10) with pressure
compensator (5) and the load holding check valves (11). The directional control valve can be arranged with
pressure relief valve and anticavitation valves (2) or only anticavitation valves, or only plugs.
The control spool (10) is spring centered by the spring seat and spring (8) from each side and is closed both
sides by the cover (7).
The throttle valves one way (1) are located in the covers.

Fig. 5 - Directional control valve

13 11
4 11 5 3 6

A B
2
2

P'
12 12
a b

1 1
8 14 9 10 9 15 8
15 64

b B A

2 2
1

T
8
10
11
3
P"
P'

11 13

Ls 5 8
1
P P
Ls Ls

a
21599 60406991

1 Throttle valve one way - 2 Pressure relief and anticavitation valve - 3 Housing - 4 User port A - 5 Pressure
compensator - 6 User port B - 7 Cover - 8 Spring - 9 Spring seat - 10 Control spool - 11 Load holding check valve
- 12 Spool stroke limits - 13 Spring compensator spool - 14 Pilot pressure port a - 15 Pilot pressure port b.

Note - The figure shows the directional control valve relate to arm section with control spool in neutral position.
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OPERATION PRINCIPLE CV4-3-8
(O/P)
CONTROL VALVE EX135W

• Function of the directional control valve, one user operated

With all spools in the neutral position, so all user ports are closed (see Fig. 5). The Load Sensing line is free
of pressure.
The spools of pressure compensators (5) are at the lowest stroke end by the force of the spring (13).When
one pilot device operates, the pilot oil goes, for example, to a port (14) over the throttle valve with the free flow
check (1) to the spring chamber (8). By this pilot pressure the control spool (10) is shifted in proportional way
to the pressure signal.
The oil out of the channel P goes to the chamber P' below the pressure compensator (5). The spool of the
pressure compensator moves against the weak spring (13) upward. A pressure is signalled into the Load
Sensing line.
The pump begins to supply oil at a pressure equal to the load plus the ∆p (20 bar).
The connection P' to P" is opened now. When the pressure increases above the load pressure, the load holding
check valve opens the path P" and the oil flow comes to the user port A or B depending on the side selected.
The user starts moving with the control speed given by the pilot valve.
The pressure P' is equal to P" (spring unconsidered) and the Load Sensing pressure corresponds the user
pressure in A. The pressure compensator must not do any load compensation (therefore is completely
opened).
The main pump generates the flow according to the requirement as selected by the pilot maintaining constant
the ∆p pressure before and behind the spool control. The ∆p value is set on the Load Sensing controller of
pump (1.1).
This flow will remain constant if the control spool opening will not change.
Subsequently, the preselected speed of the user, remains constant apart from the load of user, if it remains
out of pump power controlling area.

• Function of directional control valve, several users operated

If during the operation previously described, several users are operated, a signal coming from user with highest
load is supplied to the pump through the Load Sensing channel.
The pump modifies its condition, supplying a flow equal to the sum of the flows required from the several users
to the pressure value determined by the user that works with highest load (see Fig. 6).

This signal has an influence also on the pressure compensators that are working with lower load in the following
way:

A) The pressure compensator of user with highest load is completely opened.

B) All control valve compensators receive the signal from the rear side (spring side) closing them; in this way
the pressure after control spools will be equal for all users, because it is no more dependent on user but
on the load generated by the same compensators.

C) The compensators of the users that work at lower load of the compensator of the above point A), assume
a position so as to maintain constant the pressure after the control spools, and to compensate the pressure
difference between the load required and that supplied from pump.

Higher is the pressure difference between pump load and user load, and smaller is the clearance of the opening
passage from compensator toward the user.
19400 60406991
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OPERATION PRINCIPLE CV4-3-9
(O/P)
CONTROL VALVE EX135W

Fig. 5A - Pressure compensator

F3352

Fig. 6 - Schematic diagram of function with several users

50 bar 100 bar 150 bar

50 l/min. 50 l/min. 50 l/min.

Pressure Compensator
of user with highest load
21599 60406991

Main pump
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OPERATION PRINCIPLE CV4-3-10
(O/P)
CONTROL VALVE EX135W

Note: Control spool axis in neutral position. The user not operates.

Fig. 7

Note: Control spool in position for user operation of A side.

Pilot control valve at the stroke end.
Side B: return from the user.

Fig. 8 A B

P' P"
P'
A PA PB B

P' P
T

a b

Note: Pressure compensator in the control function of a lower loaded user while an another control spool is
operating with an high load.

Fig. 9
21599 60406991

P' P"
A PA PB B

P' P
T

a b
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OPERATION PRINCIPLE CV4-3-11
(O/P)
CONTROL VALVE EX135W

Pressure relief and anticavitation valve description

• Construction

The pressure relief and anticavitation valve (see fig. 10) is screwed on directional control valve and consists
of housing with main and pilot valve.
The main valve consists of spool (3) with needle spool (9) and is maintained closed by the pressure action in
chamber B (4).
The spring (5) press against the valve seat (19) as return spring.
The pilot valve consists of poppet valve (14), which is closed by the spring action (15) onto the valve seat (13).
The spring force (15) on the poppet valve (14) can be adjusted by the screw (7) allowing the relief pressure
setting.

• Pressure relief valve function

When the pressure from chamber A (1) via the channel (8, 12) in the chamber B (4) reaches the value set at
poppet valve (14), this opens it.
The oil behind the poppet valve (14) in chamber C (6) escapes over the channels (17, 18) to the chamber D
(10). By this the pressure drop in chamber B (4) takes place. The needle spool (9) moves to the right and sits
with its hollow cavity at the head on to the tip of the poppet (14). A throttled flow takes place from chamber A
(1) to the chamber B (4) now. By these two measures the valve is stabilized.
The pressure in chamber B (4) is reduced now to a ratio A : B = 1 : 1.4. The user pressure in chamber A (1)
opens the spool (3) and allows oil to flow to the chamber D (10).

As long as the hydraulic force which acts at the front area of the needle spool (9) equalises the mechanical
force of the adjustment spring (15) and the pilot poppet valve (14) remains open, the load pressure in the
chamber A or B can be limited.

If the pressure in the user chamber A or B drops now so far, the spring force (15) of the poppet valve (14)
presses against the seat (13) and prevents an oil flow from the chamber C (6) to the chamber D (10).
By the throttled oil flow over the clearance (12) to the chamber B (4), its pressure reaches and equalises to
the pressure of chamber A (1).
The spool (3) closes and the needle spool reaches its rest position by the force of the spring (5).
The pressure relief valve, used in pairs, are installed on directional control valve related to arm, boom and
bucket.
The pressure relief valve, used as main pressure relief of the main pump circuit is installed directly on right
body (M7) of control valve. The setting values of each pressure relief valve are shown on hydraulic diagram
of Fig. 2.

• Anticavitation valve function

If in the chamber A (1) an underpressure occurs, so that a differential pressure related to chamber D (10) is
generated, the spool (3) is shifted and opens the connection between chamber A (1) and chamber D (10).
21599 60406991
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OPERATION PRINCIPLE CV4-3-12
(O/P)
CONTROL VALVE EX135W

Fig. 10 - Pressure relief and anticavitation valve

3
2 4 (B)
5 6 (C)
19
16 7
1 (A) 20
9
8
12
20
10 (D)

17

13 14 18 15

re
su
es
/Pr
ne
7 Pre
ssio

15

14

Attention to spool seal

assembly position.
For installation a tool is
20 necessary.

F3351

1 - Chamber A 12 - Clearance
2 - Effective spool area 13 - Valve seat
21599 60406991

3 - Spool 14 - Poppet valve

4 - Chamber B 15 - Spring
5 - Spring 16 - Effective spool are
6 - Chamber C 17 - Channel
7 - Adjusting screw 18 - Channel
8 - Channel 19 - Valve seat
9 - Needle spool 20 - Pressure relief and anticavitation valve
10 - Chamber D
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OPERATION PRINCIPLE CV4-3-13
(O/P)
CONTROL VALVE EX135W

Cut off valve

The pressure related to maximum load is limited by the direct acting of the cut off valve (see fig. 11).
The valve operates on the Load Sensing line and prevents the increase of pressure above the setting value
of 280 ± 5 bar.

• Construction and function

The valve essentially consists of the housing, the poppet (1), spring (3) and adjusting screw (4). The spring
(3) acts upon the poppet (1) on its seat. The channel P is connected to the Load Sensing line. The pressure
in the Load Sensing line acts upon the poppet surface.
If the existing pressure in the channel P exceeds the spring (3) setting, the poppet (1) opens against the spring
(3). The fluid flows from channel P to channel T.
The pressure adjustment is performed by the adjusting screw (4).
Reaching the spring setting value, the poppet (1) opens and puts to drain the Load Sensing signal, so that
the pressure on main line is limited.

Fig. 11 - Cut off valve

5 1
3 2

T
P

P
T
6
4
6
6
4
21599 60406991

F3344

1 Poppet - 2 Control line - 3 Spring - 4 Adjustable screw - 5 Valve seat - 6 Cut off valve.
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OPERATION PRINCIPLE CV4-3-14
(O/P)
CONTROL VALVE EX135W

Anticavitation valve

• Construction

The anticavitation valves (Fig. 12) are screwed on the directional control valve related to travel and positioning
sections, and consist of a housing (9), with valve seat (5) within the spool (8) can shift against a spring (4).

• Function as check valve

The user pressure in the channel B is applied via the channel (7) in the chamber (3), spring (4) side. Because
of the effective area, the spool is held in the seat and the connection to tank port is prevented.

• Function as anticavitation valve

If in the channel B (1) an underpressure occurs so that a differential pressure relate to channel T (6) is
generated, the spool (8) is shifted and opens the connection between channel B (1) and channel T (6).

Fig. 12 - Anticavitation valve

5 2 3 9 10

8
B
1
7
T
6 4 10

10

F3349
21599 60406991

1 - Channel B 6 - Channel T
2 - Effective spool area 7 - Channel
3 - Spring chamber 8 - Spool
4 - Spring 9 - Housing
5 - Valve seat 10 - Anticavitation valve
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OPERATION PRINCIPLE CV4-3-15
(O/P)
CONTROL VALVE EX135W

Unloading valve

• Construction

It includes a block fastened to control valve (M7) right body, a spool and a cursor which keeps oil at disposal
for control user.

• Function

Main pump never stops sending oil to control valve. Unloading valve discharges oil directly when no control
is used and guarantees a minimum quantity of oil for the control if used; this allows a prompt response at control
operation.

1 - Channel B
Fig. 12 A - Unloading valve 2 - Effective spool area
3 - Spring chamber
4 - Spring
5 - Valve seat

4
3
4 2
5 1
1
21599 60406991

F6894
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OPERATION PRINCIPLE CV4-3-16
(O/P)
CONTROL VALVE EX135W

3.1.3 CONTROL VALVE CENTRAL BODY

In the central body of control valve (Fig. 13) are located:

• the flow limiter valve;
• the radiator by-pass valve;
• the drain pressurisation valve.

Fig. 13 - Control valve central body

4 1

2
1

2 3

4
K S

5.5 bar

4
0.7 l/min.

1 - Central body manifold plate 7.1 bar

2 - Flow limiter valve

3 - By-pass valve
4 - Drain pressurisation valve T

T = 7.1 bar
K = 5.5 bar
21599 60406991
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OPERATION PRINCIPLE CV4-3-17
(O/P)
CONTROL VALVE EX135W

Flow limiter valve

The flow limiter valve (Fig. 14) is installed on the Load Sensing line in parallel to the cut off valve in the central
body of control valve.
The valve has two functions:
• When no user is operated (all control spool axis are in neutral position) the flow limiter valve releases the
Load Sensing line to the tank.
• If a user runs against the maximum pressure (i.e. to the cylinder stroke end) and another user is operated,
the pressure drop generated before and after control spool axis is used to control the pump flow through the
moving of swivel cylinder plate.

The flow of Load Sensing line that pass through the flow limiter valve while another user is operating, is used
to check the position of the pump swivel plate from stroke end of minimum flow.

• Construction and function

The flow limiter valve consists of a gauging orifice and a pressure compensator with a control spool.
The pressure compensator holds the pressure drop over the gauging orifice in the flow condition, to a constant
value.
By that the flow is maintained constant to the predesigned value.
The gauging orifice controls the flow going out to the value of 0.7 liter/minute.
In the initial position the port P is opened to tank, while in flow condition the pressure in the spring chamber
is lesser than the amount of pressure drop caused by the gauging orifice.
The nominal ∆p is determined by the spring. If the flow going to the port T is higher than 0.7 l/min., the pressure
drop increases, the control spool moves and reduces the outgoing flow so far as the difference of pressure
in P and in the spring chamber corresponds to the nominal ∆p value.

Fig. 14 - Flow limiter valve

P
21599 60406991

Flow limiter valve

F3347
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OPERATION PRINCIPLE CV4-3-18
(O/P)
CONTROL VALVE EX135W

Drain pressurisation valve

The pressurisation and check valve installed on control valve central body (Fig. 13), is operated by the pressure
returns.
It allows the oil flow when the pressure is higher than 5,5 bar.
The oil flow, that goes through the valve, escapes of the central body (port K) and reaches the oil radiator where
it is become cold and sent to the tank.

Radiator by - pass valve

The radiator by-pass valve, installed on control valve central body (Fig. 13), is actuated from users drain
pressure.
It allows the oil flow when the pressure is higher than 7.1 bar.
The oil flow that goes through the valve, leaves the central body (port T) and directly reaches the oil tank, by-
passing the oil radiator.
This valve normally works with low temperature of hydraulic oil, or in case of radiator clogging.

3.1.4 CONTROL VALVE LEFT BODY

The control valve is a traditional open center type.

In the left body (M8) (Fig. 15) are located the directional control valves related to:
6 - Blade and/or lateral stabilizers;
7 - Swing.
As for the right body, each directional control valve consists of a control spool, two conduits A and B connected
to the users, and two conduits a and b connected to the control pilot devices.
On the control valve left body, is installed a secondary pump pressure relief valve set at 330 bar.
Only on the pilot pressure input related to swing control are applied, externally of control valve body, two throttle
valve one way. These are connected so that the input pilot pressure is with free flow and the orifice controls
the return phase so as to provide a calibrated damping action.

ATTENTION
Each individual directional control valve is matched to the requirements of user. Therefore the spools
of directional control valves are not interchangeable to each other.

The function of each directional control valve is to transfer the hydraulic oil flow demand to the users in
proportional way to the pressure signal coming from pilot valve and in relation with the applied load (traditional
circuit).
21599 60406991
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OPERATION PRINCIPLE CV4-3-19
(O/P)
CONTROL VALVE EX135W

Fig. 15 - Control valve left body

1 2

7
5
b6 b7

ø 0.8
C A6 B6 A7 B7 M2
3

4
1 6
6

330 bar
3

2
1 - Control valve left body
2 - Secondary pump pressure relief valve P2

ø 0.8
3 - Anticavitation valve
4 - Blade/lateral stabilizers control spool
5 - Swing control spool a6 a7

6 - Check valve 3 3 7
7 - Throttle valve one way (Ø 0.8)

4/5

7
7
21599 60406991
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OPERATION PRINCIPLE CV4-3-20
(O/P)
CONTROL VALVE EX135W

Fig. 16 - Secondary pump pressure relief valve

1 - Plug
2 - Valve

F3350

Fig. 17 - Anticavitation valve

6
21599 60406991

1 - Cover 7
2 - Nut
3 - Adjusting screw
4 - Spring
5 - Poppet valve F3353

6 - Spool
7 - Valve
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DISASSEMBLY AND ASSEMBLY CV4-3-1
(D/A)
CONTROL VALVE EX135W

3.1 CONTROL VALVE

3.1.1 MAINTENANCE

The control valve maintenance essentially consists of:

- clean and check operations of the following components:

• arm control spool (35);

• boom control spool (36);
• travel control spool (37);
• positioning control spool (38);
• bucket control spool (39);
• blade/lateral stabilizers control spool (41);
• swing control spool (42);

- clean, check and, if necessary, replacement of the following valves:

• main pressure relief valve (6);

• pressure relief and anticavitation valve (3);
• throttle valve - one way (28);(29),(30);
• throttle valve - two ways (9);
• anticavitation and check valves (4);
• cut off valve (7);
• flow limiter valve (14);
• drain pressurisation valve (27);
• pressure compensator (8).

CAUTION - The weight of the control valve is about 160 kg (353 lb).

3.1.2 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE BODIES

Note - Before starting the disassembly procedures:

• carefully clean the external surface of control valve;
• replace seals and O-rings, whenever it needs to proceed disconnection of control valve bodies.

1 To disconnect the left body M8 (24) from central body (15), loose the four fixing screws (20) M12x80.

2 To disconnect the right body M7 (1) from central body (15), loose the four fixing screws (47) M12x100.

3 Replace seals and O-rings.

4 To reassemble, perform the procedures previously described, in reverse order.

5 Tighten the fixing screws to the proper torque, according to the table at paragraph 1-7.
21599 60406991
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DISASSEMBLY AND ASSEMBLY CV4-3-2
(D/A)
CONTROL VALVE EX135W

3.1.3 DISASSEMBLY AND ASSEMBLY OF THE CONTROL SPOOLS OF DIRECTIONAL CONTROL

VALVES

Control spools of control valve right body (M7)

Note - The involved control spools to the following disassembly are.

• arm control spool (35);
• boom control spool (36);
• travel control spool (37);
• positioning control spool (38);
• bucket control spool (39).

ATTENTION
• Each individual directional control valve is matched to the requirement of the user. Therefore the
spools of directional control valve are not interchangeable to each other, and must not overturn
respect to the original position.
• The spring seat covers (31) absolutely must not exchange each others.
• Do not change the setting position of the adjusting screws (33) of spool stroke end. In case of need
to remove that adjusting screws, it is requested, before removing, to detect accurately the setting
position by measuring the length between the head screw and lock nut, in order to be able to reinstall
the screws to their same original position.

1 Loose the fixing screws (32) of spring seat covers (31).

2 Extract the covers (31), without changing the position of relate adjusting screws(33).

3 Extract the control spools, be care to note their position in order to reinstall in the correct way.

4 Proceed to the assembly, carrying out the procedures previously described, in reverse order.

5 Tighten the fixing screws (32) to the proper torque, according to the table at paragraph 1.7.

Control spools of control valve left body (M8)

Note - The spools involved in the following disassembly are:

• blade/lateral stabilizer control spool (41);
• swing control spool (42).

ATTENTION
• Each individual directional control valve is matched to the requirement of the user. Therefore the
spools of directional control valve are not interchangeable to each other, and must not overturn
respect to the original position.
• The spring seat covers (44) absolutely must not exchange each others.

1 Loose the fixing screws (32) of spring seat cover (44).

21599 60406991

2 Extract the covers (44).

3 Extract the control spools, be care to note their position in order to reinstall in the correct way.

4 Proceed to the assemble, carrying out the procedures previously described, in reverse order.

5 Tighten the fixing screws (32) to the proper torque, according to the table at paragraph 1.7.
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DISASSEMBLY AND ASSEMBLY CV4-3-3
(D/A)
CONTROL VALVE EX135W

3.1.4 DISASSEMBLY AND ASSEMBLY OF RIGHT BODY (M7) VALVES

Note - The involved valves in the following disassembly are:

• pressure relief and anticavitation valves (3);
• anticavitation and check valves (4);
• main pressure relief valve (6);
• pressure compensator (8).

Note - Before starting the disassembly procedures:

• carefully clean the external surface of right body of control valve;
• replace seals and O-rings, whenever it needs to proceed to the disassembly of a valve.

1 For disassembling of a valve, loose directly on the body of the relevant valve.

2 Proceed to the re-assemble, or to the replacement, be care to close the valve body to the proper torque,
according to the table at paragraph 1.7.

3.1.5 DISASSEMBLY AND ASSEMBLY OF CENTRAL BODY VALVE

Note - The involved valve in the following disassembly is:

• flow limiter valve(14).

Note - Before starting the disassembly procedures:

• carefully clean the external surface of central body of control valve;
• replace seals and O-rings, whenever it needs to proceed to the disassembly of a valve.

1 For disassembling of the valve (14), loose directly on the body of the relevant valve.

2 Proceed to the re-assemble, or to the replacement, be care to close the valve body to the proper torque,
according to the table at paragraph 1.7.

3.1.6 DISASSEMBLY AND ASSEMBLY OF LEFT BODY (M8) VALVES

Note - The involved valves in the following disassembly are:

• secondary pump pressure relief valve (19);
• anticavitation valve (21);
• check valve (22).

Note - Before starting the disassembly procedures:

• carefully clean the external surface of left body of control valve;
• replace seals and O-rings, whenever it needs to proceed to the disassembly of a valve.

1 For disassembling of a valve, loose directly on the body of the relevant valve.
21599 60406991

2 Proceed to the re-assemble, or to the replacement, be care to close the valve body to the proper torque,
according to the table at paragraph 1.7.
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DISASSEMBLY AND ASSEMBLY CV4-3-4
(D/A)
CONTROL VALVE EX135W

ITEM NAME
1 Control valve right body
2 Plug
3 Pressure relief and anticavitation valve
4 Anticavitation and check valve
5 Plug
6 Main pressure relief valve
7 Cut off valve
8 Pressure compensator
9 Throttle valve -two ways
10 Check valve
11 Plug
12 Plug
13 Orifice
14 Flow limiter valve
15 Control valve central body
16 By-pass valve
17 Plug
18 Plug
19 Secondary pump pressure relief valve
20 Fixing screw
21 Anticavitation valve
22 Check valve
23 Plug
24 Control valve left body
25 Plug
26 Plug
27 Drain pressurisation valve
28 Throttle valve - one way Ø 1.4
29 Throttle valve - one way Ø 1.2
30 Throttle valve - one way Ø 0.8
31 Spring seat cover
32 Fixing screw
33 Spool stroke end adjusting screw
34 Spring
35 Arm control spool
36 Boom control spool
37 Travel control spool
38 Positioning control spool
39 Bucket control spool
40 Plug
41 Blade/Lateral stabilizers control spool
42 Swing control spool
43 Spring
21599 60406991

44 Spring seat cover

45 Throttle valve - one way Ø 0.8
46 Cover
47 Fixing screw
48 Fixing screw
49 Unloading Valve
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DISASSEMBLY AND ASSEMBLY CV4-3-5
(D/A)
CONTROL VALVE EX135W

48

49
3
2
1 10

10
5

10

10
10
3

3 6
10

4
10 7

9
8
3

13
20 12
14
11

15 47
26
17 18
25

19
24

17 21
21599 60406991

18

21
22
23
F3345
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DISASSEMBLY AND ASSEMBLY CV4-3-6
(D/A)
CONTROL VALVE EX135W

35

36
28/29/30

37

31 38
32
39

33 40

28/29
34

33

31 32

34

41/42 11

32
44
46

11
43
45
32
21599 60406991

45

32
11 44
43
46
32 F3346
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DISASSEMBLY AND ASSEMBLY CV4-3-7
(D/A)
CONTROL VALVE EX135W

3.1.7 TIGHTENING TORQUE

ITEM NAME TIGHTENING TORQUE

Nm
2 Plug 60
3 Pressure relief and anticavitation valve 120
4 Anticavitation and check valve 120
5 Plug 120
6 Main pressure relief valve 120
7 Cut off valve 25
8 Pressure compensator 200
9 Throttle valve -two ways 30
10 Check valve 100
11 Plug 30
12 Plug 15
13 Orifice 6.5
14 Flow limiter valve 20
17 Plug 36
18 Plug 90
19 Secondary pump pressure relief valve 90
20 Fixing screw 130
21 Anticavitation valve 90
22 Check valve 100
23 Plug 9
25 Plug 90
28 Throttle valve - one way Ø 1.4 20
29 Throttle valve - one way Ø 1.2 20
30 Throttle valve - one way Ø 0.8 20
32 Cover fixing screw 10.4
40 Plug 20
45 Throttle valve - one way Ø 0.8 20
47 Fixing screw
48 Fixing screw 130
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DISASSEMBLY AND ASSEMBLY CV4-3-8
(D/A)
CONTROL VALVE EX135W

NOTES:

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OPERATION PRINCIPLE SRD4-4-1
(O/P)
SWING DEVICE EX135W

4. SWING DEVICE

4.1 SWING DEVICE

4.1.1 OUTLINE

The swing device consists of an hydraulic motor and a swing reduction device.
The hydraulic motor is an axial piston motor.
The swing reduction carries out the upperstructure swing movement by means of motor pinion matching to
the inner race of swing bearing.
The swing device is located on main frame of upperstructure.

Hydraulic diagram

Swing hydraulic
motor

Swing reduction
device

Swing hydraulic
motor

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OPERATION PRINCIPLE SRD4-4-2
(O/P)
SWING DEVICE EX135W

4.1.2 SPECIFICATIONS AND DATA

Swing reduction device technical data

Maximum torque ........................................................................................................................... 504 daNm

Ratios ................................................................................................................................................. 1 : 31.9
Maximum input rate of turn ............................................................................................................ 1750 rpm
Oil quantity ............................................................................................................................... 3 litres ± 10%
Weight (*) ................................................................................................................................. 70 Kg ± 10 %
Braking static torque .......................................................................................................... 18,5 daNm ± 5 %
Minimum opening pressure ................................................................................................................ 5,5 bar
Maximum control pressure .................................................................................................................. 50 bar
Static load coefficient of bearing C1 ......................................................................................... 15600 daNm
Static load coefficient of bearing C2 ......................................................................................... 30000 daNm
Dynamic load coefficient of bearing C1 .................................................................................... 12500 daNm
Dynamic load coefficient of bearing C2 .................................................................................... 20900 daNm

(*) Without oil and with swing hydraulic motor.

Swing motor technical data (theorethical values)

Type ................................................................................................................................. A2FE 32/6.1 AB05
Displacement ........................................................................................................................................ 32 cc
Maximum speed ............................................................................................................................. 2813 rpm
Maximum flow ............................................................................................................................ 50 litres/min
Weight ................................................................................................................................................ 10.5 kg

2
5

2 - Fill plug - oil level and exhaust

M22 x 1.5
3 - Brake control M14 x 1.5
4 - Drain oil plug M22 x 1.5
5 - Swing relief valves (Q.ty 2)

4
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F11053
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OPERATION PRINCIPLE SRD4-4-3
(O/P)
SWING DEVICE EX135W

4.2 SWING HYDRAULIC MOTOR

4.2.1 DESCRIPTION

The swing hydraulic motor consists of an axial pistons motor. The motor receives oil coming from the control
valve, that operates on pistons, and causes the drive shaft rotation.
The direction of rotation of swing hydraulic motor is depending on which input port the oil is fed.
The axial pistons motor consists of a cylinder block (3) containing seven pistons (4), that can slide into their
seats. The cylinder block (3) turns together the output shaft (1) when the pistons shift with alternative motion.
The seven pistons (4) are installed on spherical couplings.
The cylinder block (3) is tilted respect to the output drive shaft (1): The control plate (5) is in contact with the
cylinder block end(3): The tilt angle of cylinder block(3) is 40°.

F6960

7
5 1
2
3
6

1 - Output drive shaft

2 - Retaining disc
3 - Cylinder block
4 - Piston
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5 - Control plate
6 - Center pin
7 - Port plate
8 - Swing relief valves
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OPERATION PRINCIPLE SRD4-4-4
(O/P)
SWING DEVICE EX135W

4.2.2 OPERATION PRINCIPLE

The drive shaft (1) complete with the retaining disc is supported by bearings in such way to allow the retaining
plate to turn freely.
If a force (F) is diagonally applied to the retaining disc, this force is decomposable in its two components (F1
- perpendicular to the disc) and (F2 tangential to the circumference of the disc). The force (F1) pushes the disc
in the axial direction, meanwhile the force (F2) operates to turn clockwise the disc.
If a force (F') is applied to the disc, this similarly can be decomposed in the components (F'1) and (F'2), where
(F'2) causes to turn counterclockwise the disc.

When the oil enters in the left ports of control plate (5) and goes out through right ports, the oil pressure is
applied to the rear faces of the pistons (4) connected to the left ports and the output drive shaft (1) turns
clockwise.
In this case, the pistons (4) turn clockwise together the cylinder block (3) to the same speed of the output shaft
(1), shifting into the inner of the cylinder block (3).
Subsequently, when the piston (4) reaches the top dead point, the cylinder of the same piston is put to
connection with the output drain ports of control plate (5).
When the pistons (4) reach the output drain ports, the pressure on the rear faces of pistons leaves off,
cancelling in this way the applied force to the output drive shaft (1).
Subsequently, the pistons (4) are put in rotation by output drive shaft (1) and they move in alternative direction
in the cylinder block (3).
The existing oil on the rear faces of pistons is drained to the tank.
The movements described above, are common for all the seven pistons (4) and the output drive shaft (1) turn
clockwise. If the suction and drain ports are used in reverse direction, the movements previously described
are performed in reverse order and the output drive shaft (1) turns counterclockwise.
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OPERATION PRINCIPLE SRD4-4-5
(O/P)
SWING DEVICE EX135W

4.2.3 SWING RELIEF VALVES

Description

Two swing relief valves are installed on ports plate of swing motor. The valves are double stage type with two
different setting adjustment hydraulically controlled by external piloting.
The purpose of these valves is to protect the hydraulic circuit from pressure peak that can take place during
the swing starting phase of upperstructure and to limit the pressure in the swing circuit during the
upperstructure braking phase. Furthermore, these valves operate also as anticavitation valves.
By operation of the pilot valve, the hydraulic pilot pressure, (other than to the control valve) is fed to the brake
disengagement circuit on the swing reduction device through the throttle valve -one way, and the swing relief
valve relevant to swing direction set up.
With pilot pressure applied, the relief valve release to the drain at 320 bar.
When the pilot valve is taken back to neutral position (upperstructure braking phase), the pilot pressure is shut
off and the swing relief valve release the pressure at 180 bar.
Shutting off the pilot pressure, a throttle valve-one way allows the brake engagement with a certain delay
respect to swing stopping of upperstructure.

4 2 3

1
1

2-3

6
5

F11054
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1 Swing relief valves - 2 Throttle valve-one way - 3 Shuttle valve - 4 Brake swing - 5 To control valve - 6 To pilot valve.
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OPERATION PRINCIPLE SRD4-4-6
(O/P)
SWING DEVICE EX135W

Operation principle

When the pressure in the chamber (C), connected through the duct (8) with the chamber (A), reaches the
setting value adjusted by means of spring (M), the poppet valve (F) rises and connects the chamber (C) with
chamber (B) in low pressure.
In this way the spool (O) is pushed toward the high by the pressure in (A).
The oil is therefore released in the channel (B) limiting, in this way, the overpressure on the line (A).
As shown in the figure, the channel (B) is common for both valves, this because the oil that is released through
the channel (B), is not sent to drain, as usual, but is used to supply again the swing motor avoiding in this way,
the anticavitation effect on hydraulic motor.
Therefore, the swing relief valve also carries out the anticavitation function when the pressure on side (B) is
bigger than the pressure in the channel (A). In this situation the oil pressure working against the section (S),
overcomes load spring (M1) which holds the spool in position, allowing the oil transfer between chamber (B)
and chamber (A).

M M

F F
8 8
M1 C C
M1
S S
O O

A
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F3410
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OPERATION PRINCIPLE SRD4-4-7
(O/P)
SWING DEVICE EX135W

4.3 SWING REDUCTION DEVICE

4.3.1 DESCRIPTION

The swing reduction device is used to transfer the swing movement to the upperstructure.
The swing reduction device has an epicycloid final reduction from which the force is transfer, by means of
drive shaft with built pinion (1) to the inner gear race bearing.
All gears, including the pinion shaft, are obtained from highly alloy steel.
The gears of planet carriers groups and the pinion are case-hardened and tempered.
The reduction housing (2) is built in spheroidal cast-iron.
The forged pinion is built in only one piece with the drive shaft, is cemented, tempered, and rectified, and it
allows to obtain, with reduced number of teeth, high reduction ratios between pinion and race bearing.
The pinion shaft is sustained by a couple of bearings (3) and (4). The swing reduction components are lubricate
by oil immersion.
The swing reduction is equipped with multiple discs brake (5) spring loaded (6) that, with machine at standstill
are locked from integrated spring action.
Only when the pilot pressure is applied, the springs force are overcome, open the discs, and unlock the brake,
allowing the swing movement.
The brake group, together with the swing reduction, makes only one assembly.
The swing reduction device is completed with a flange to allow the fixing on the machine.

4
2
3 1
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5
5

F7007
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OPERATION PRINCIPLE SRD4-4-8
(O/P)
SWING DEVICE EX135W

NOTES:

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DISASSEMBLY AND ASSEMBLY SRD4-4-1
(D/A)
SWING DEVICE EX135W

4.1 SWING HYDRAULIC MOTOR

Note - Before starting the disassembly, clean accurately the outside of swing hydraulic motor, then loose fixing
screws, drain the oil, disconnect the related hydraulic hoses and lift the swing device by means of an hoist.
Whenever swing motor disassembly is performed, it is advisable to replace the O-rings, seals and bearings,
because it is difficult to determine visually the remaining useful life.

CAUTION - The approximate weight of swing hydraulic motor is = 10.5 Kg.

4.1.1 SHAFT SEALS

1 Free circlip and remove.

2 Prise off front cover.

3 Visual check:
• Shaft seal (1).
• Cover (2).
• Drive shaft (3).
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• Housing (4).
• O-ring (5).
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DISASSEMBLY AND ASSEMBLY SRD4-4-2
(D/A)
SWING DEVICE EX135W

4 Remove shaft seal.

5 Press in the shaft seal ring to the correct position

with a suitable sleeve.

6 Fit new O-ring, ensure it is a snug fit. Grease O-

ring and lips of shaft seal.

7 Fit circlip using a punch. Check that circlip is well

seated.
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DISASSEMBLY AND ASSEMBLY SRD4-4-3
(D/A)
SWING DEVICE EX135W

4.1.2 COVER PLATE

1 Mark position of cover plate (arrow). Remove

screws.

2 Swing port plate on locating pin and lift off.

3 Note position of locating pin (arrow).

4 Visual check:
• O-ring (1).
• Groove (2).
• Plate (3).
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DISASSEMBLY AND ASSEMBLY SRD4-4-4
(D/A)
SWING DEVICE EX135W

5 Lightly grease and fit O-ring.

6 Install the port plate to the correct position, noting

to align it to the marks, previously signed.

7 Tighten screws using torque wrench. For torque

tightening setting, make reference to the table at
the end of paragraph.

8 Motor, bi-directional. (Viewd on spherical

surface).
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F7008
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DISASSEMBLY AND ASSEMBLY SRD4-4-5
(D/A)
SWING DEVICE EX135W

4.1.3 ROTARY GROUP

1 Mark position of cover plate (arrow). Remove

screws.

2 Swing port plate on locating pin and lift off.

3 Free circlip and remove.

4 Prise off the front cover.

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DISASSEMBLY AND ASSEMBLY SRD4-4-6
(D/A)
SWING DEVICE EX135W

5 Remove the shim(s).

6 Remove rotary group with extractor.

7 Loosen the screw, then remove retaining plate.

Note - The screws are held by Loctite.

8 Before proceeding to the assembly of rotary

group, it needs to perform the following check: 3

• Drive shaft
1. Should be free of corrosion or erosion. no 3
damage to spline.
2. No trace of wear, free of scratches.
3. Cups free of scratches and no pitting.
1 2

9 Remove front cover.

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DISASSEMBLY AND ASSEMBLY SRD4-4-7
(D/A)
SWING DEVICE EX135W

• Piston
1.Axial play of piston. 2 2
2.Should be free of scratches.

• Centre pin
1.Should be free of scratches, no pitting. 2
2.Should be free of scratches. 1

• Retaining plate
1.Free of scratches, no wear.

• Cylinder block and control plate

1.Bore unscratched, and not worn.
2.Faces, smooth and even, no cracks or
scratches. 2
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DISASSEMBLY AND ASSEMBLY SRD4-4-8
(D/A)
SWING DEVICE EX135W

• Bearings housings
1. No damage or wear.

9 Insert centre pin with retaining ring.

Correctly fit retaining plate.

10 Apply Loctite sparingly to the fixing screws only.

11 Heavily grease then fit spring pad and Belleville

washers.
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DISASSEMBLY AND ASSEMBLY SRD4-4-9
(D/A)
SWING DEVICE EX135W

12 Make sure all parts are fitted in correctly.

13 Fit pistons in the relate bores.

14 Press pistons in the relate cups with cylinder

block held in central position.

15 Swivel cylinder block to maximum.

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DISASSEMBLY AND ASSEMBLY SRD4-4-10
(D/A)
SWING DEVICE EX135W

16 Heat housing at 80°C.

80°C

17 Install preheated housing to stroke, then

reposition the unit.

18 Install shims, if necessary.

19 Lay rotating unit to closing plate. Check if plate

position is correct.
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DISASSEMBLY AND ASSEMBLY SRD4-4-11
(D/A)
SWING DEVICE EX135W

20 After assembling the shaft seal, install the circlip

using a punch. Check for correct position of circlip
into its seat.

21 Install seal ring after applying a film of grease.

22 Install the port plate to the correct position, noting

to align it to the mark previously signed.

23 Tighten screws using torque wrench for setting.

For tightening torque, make reference to the table
at the end of the paragraph.
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DISASSEMBLY AND ASSEMBLY SRD4-4-12
(D/A)
SWING DEVICE EX135W

4.1.4 TIGHTENING TORQUE

THREAD BOLT HARDNESS GRADE

8.8 10.9 12.9

Nm/ftlb
M3 1.08/0.78 1.6/1.15 1.9/1.37
M4 2.84/2.05 4.0/2.89 4.8/3.47
M5 5.90/4.26 8.3/6.00 9.8/7.09
M6 9.80/7.09 14/10.1 17/12.2
M8 24/17.3 34/24.5 40/28.9
M10 48/34.6 68/49.1 81/58.5
M12 84/60.6 118/85.2 142/102.5
M14 132/95.3 186/134.3 226/163.2
M16 206/148.7 289/208.6 348/251.3
M18 284/205.0 397/286.6 476/343.7
M20 402/290.2 569/410.8 677/488.8

THREAD Nm ftlb

M12 x 1.5 20 14.5

M22 x 1.5 60 43.3
M26 x 1.5 70 50.6
M33 x 2 120 86.8

THREAD Nm ftlb

M12 x 1.5 30 21.7

M14 x 1.5 40 28.9
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DISASSEMBLY AND ASSEMBLY SRD4-4-13
(D/A)
SWING DEVICE EX135W

4.2 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION DEVICE

4.2.1 DISASSEMBLY

Note - Before starting the disassembly, clean accurately the outside of swing motor and reduction device, then
loose fixing screws, drain the oil, disconnect the related hydraulic hoses and lift the swing device by means
of an hoist.
Whenever a swing device disassembly is performed, it is advisable to replace the O-rings, seals and bearings,
because it is difficult to determine visually the remaining useful life.
In case of damaged gears, never replace a gear alone, but the complete reduction group with relate sun gear.

CAUTION - The approximate weight of swing reduction device is = 85 Kg.

Motor and brake

1 Loose the screws (25), then withdraw the hydraulic

swing motor by means of an hoist.

2 Loose the screws (38), mating the brake housing

(33) to the reduction device, then withdraw the brake
housing.
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DISASSEMBLY AND ASSEMBLY SRD4-4-14
(D/A)
SWING DEVICE EX135W

4 By means of a press, work on spring pusher disc

(22) to slacken the spring action (21).

5 Remove, by means of proper pliers, the circlip

(31).

6 Remove the spring pusher disc (22) and extract

the springs (21) from the relating piston (32).

7 Turn upside down the group, then remove the

circlip (14).
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DISASSEMBLY AND ASSEMBLY SRD4-4-15
(D/A)
SWING DEVICE EX135W

8 Remove the spacer ring (15) then extract the

brake disc package (36) and (37).

9 Using a copper hammer, work to extract the

piston (32) from brake housing (33).

10/11 Remove the seal rings (16 - 17 - 19 and 20)

then perform the relevant check.
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DISASSEMBLY AND ASSEMBLY SRD4-4-16
(D/A)
SWING DEVICE EX135W

Gears

12 Extract the brake shaft (34) keyed on the 1st

reduction sun gear (12).

13 Remove the 1st reduction sun gear (12).

14 Extract the 1st reduction complete (11).

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DISASSEMBLY AND ASSEMBLY SRD4-4-17
(D/A)
SWING DEVICE EX135W

15 Remove the 1st reduction gear crown (39).

16 Loosen screws (40) and remove the connecting

flange (9) between first and second reduction
gear crown.

17 Take off the second reduction sun gear (8).

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DISASSEMBLY AND ASSEMBLY SRD4-4-18
(D/A)
SWING DEVICE EX135W

18 Remove the second reduction gear crown (41).

19 Take off the second reduction planet carriers

group (5).

Pinion and housing

20 Loosen the locking ring nut (43) from the shaft

pinion (1) after removed the caulking. on the edge
carry out during the assembly to avoid loosening.
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DISASSEMBLY AND ASSEMBLY SRD4-4-19
(D/A)
SWING DEVICE EX135W

21 Turn upside down and loosen the fixing screws

(47) of front cover (48) of reduction housing (42).

22 By means of press remove the pinion shaft (1)

from reduction housing (42).

23 By means of an inner puller, extract the bearing

(44) from reduction housing (42), then by means
of outer puller, extract the bearing (46) from pinion
shaft (1).

Note - The swing reduction device is now

completely disassembled: therefore proceed to
the check and inspection of all the items.
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DISASSEMBLY AND ASSEMBLY SRD4-4-20
(D/A)
SWING DEVICE EX135W

4.2.2 ASSEMBLY

Pinion and housing

1 Install the lamellar ring (3) on the front cover (48).

2 Install on the pinion shaft (1), the spacer ring (2)

previously heated to the temperature of 150°C,
then insert the front cover (48) complete with
lamellar ring (3).

3 By means of a press, install the bearing (46)

previously filled with Lithium grease type AGIP
MU/EP2 on the pinion shaft (1).
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DISASSEMBLY AND ASSEMBLY SRD4-4-21
(D/A)
SWING DEVICE EX135W

4 Fill with Lithium grease type AGIP MU/EP2 the

reduction housing (42) and there install the seal
rings (45), then by means of a press install the
pinion shaft (1) complete with bearing (46) and
front cover (48) on the reduction housing (42).

5 By means of setting torque wrench, tighten the

screws (47), fixing front cover (48) to the proper
torque.
Tightening torque: 2.5 daNm.

6 Turn upside down the reduction housing (42),

and by means of a press install the bearing (44)
then screw the ring nut (43). Tighten to the proper
torque.
Tightening torque: 110÷120 daNm.
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DISASSEMBLY AND ASSEMBLY SRD4-4-22
(D/A)
SWING DEVICE EX135W

7 Caulk the ring nut edge (43), by means of a

punch, in three hollows on the shaft pinion (1) to
avoid loosening.

Gears

8 Install the 2nd reduction (5) on the pinion shaft

(1), then the O-ring (6) on its related groove on
the reduction housing (42).

9 Install the second reduction gear crown (41), then

the relate O-ring.
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DISASSEMBLY AND ASSEMBLY SRD4-4-23
(D/A)
SWING DEVICE EX135W

10 Install the connecting flange (9), tighten the

screws (40) to the proper torque:
Tightening torque: 14.5 daNm.

11 Install the second reduction sun gear (8).

12 Install the first reduction planet carriers group (11)

complete.
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DISASSEMBLY AND ASSEMBLY SRD4-4-24
(D/A)
SWING DEVICE EX135W

13 Install O-ring in the relate groove on the

connecting flange (9), then install the first
reduction gear crown (39).

14 Install the first reduction sun gear (12).

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DISASSEMBLY AND ASSEMBLY SRD4-4-25
(D/A)
SWING DEVICE EX135W

16 Install O-rings (19) and (20) on brake housing

(33).

Note - For correct installation of O-rings and

back-up rings, proceed according to the following
diagram.

A
The back-up ring must always be fitted behind
the O-ring from side of the oil pressure input port.
A - Pressure oil input.
B - Back-up ring.
C - O-ring.

B C B B

17 Install in the brake housing (33), piston (32).

18 Insert the springs (21) in the piston (32).

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DISASSEMBLY AND ASSEMBLY SRD4-4-26
(D/A)
SWING DEVICE EX135W

19 By means of a press, install the spring pusher

disc (22) then the circlip (31).

20 Turn upside the group and install the discs brake.

Starting with a sintered disc (36), following install
alternatively a steel disc (37) and with another
sintered disk till to completion.

Sintered discs ............................................ q.ty 6

Steel discs ................................................. q.ty 5

21 By means of a hand pump, connected to the port

of oil supply on brake using (33) carry out the
seal check, then align the teeth of brake disc (36)
and (37) using the brake shaft (34).

22 Holding hydraulic pressure, install the spacer (15)

and circlip (14).
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Note - Position the circlip (14) in such a way the

two holes for mounting should be centred related
to the melting drain get on housing brake.
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DISASSEMBLY AND ASSEMBLY SRD4-4-27
(D/A)
SWING DEVICE EX135W

24 Fit the O-ring (13), then install the brake group

and motor flange on swing reduction, tightening
the screws (38) to the proper torque.
Tightening torque: 5 daNm.

25 Install the hydraulic motor on swing device,

checking the correct mating between the spline
drive shaft of motor and the brake shaft (34).
Tighten the screws (25) to the proper torque.
Tightening torque: 8.6 daNm.

26 Reconnect the hydraulic connection previously

disconnect and perform the correct refill of oil.
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DISASSEMBLY AND ASSEMBLY SRD4-4-28
(D/A)
SWING DEVICE EX135W

18

25
23
22
21
17
16

32
34
15 36
14 37
13 33
38
31
39
40
41
12
11
9
8
7
6
5 42
43
44
45

47
46
3 48
2
1

F11055
19400 60406991

1 Pinion - 2 Spacer ring - 3 Seal ring - 4 Oil exhaust plug - 5 Second reduction planet carriers - 6 O-ring - 7 Screw
- 8 Second reduction sun gear - 9 Connecting flange - 10 Plug - 11 First reduction planet carriers - 12 First reduction
sun gear - 13 O-ring - 14 Circlip - 15 Spacer - 16 Seal ring - 17 Seal ring - 18 Filling and level oil plug - 21 Spring
- 22 Spring pusher disc - 23 O-ring - 25 Screw - 31 Circlip - 32 Piston - 33 Brake housing - 34 Brake shaft
- 36 Sintered disc - 37 Steel disc - 38 Screw - 39 First reduction gear crown - 40 Screw - 41 Second reduction gear
crown - 42 Reduction housing - 43 Locking ring nut - 44 Bearing - 45 Seal ring - 46 Bearing -
47 Screw - 48 Front cover.
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OPERATION PRINCIPLE PV4-5-1
(O/P)
PILOT VALVES EX135W

5. PILOT VALVES

5.1 HAND PILOT VALVE

5.1.1 OUTLINE

The pilot valve hydraulic device is an hand controlled type and operates as direct-operated pressure reducing
valve.
Pilot valve basically consists of the control lever (13), four pressure reducing valves and the housing (10).
Each pressure reducing valve consists of a control spool (6), a control spring (7), a return spring (8) and a
plunger (9).
When is in non-operative connection the control lever (13) is kept in zero position by the return spring (8).
The ports (1, 2, 3, 4 and 5) are connected to the tank port (T) via the boring (11).
With deflection of the control lever (13) the plunger (9) pushes at the same time against the return spring (8)
and control spring (7).
The control spring (7) first moves the control spool (6) downwards and closes the connection between the
appropriate port and the tank port (T). At the same time the appropriate port is connected to the port (P) via
the bore (11).
The control phase begins as soon as the control spool (6) has found its balance between the force of the control
spring (7) and the force which results from the hydraulic pressure.
Through the co-operation of control spool (6) and control spring (7) the pressure in the appropriate ports
(1,2,3,4, and 5) is proportional to the stroke of the plunger (9) and thus the position of the control lever (13).
The rubber sleeve (12) is used to protect the mechanical components of device from dust or foreign objects
entrance.

13

12

4 3 7
T 10
5
1 2
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11
P 6
T P
F3784

1, 2, 3, 4, 5 Ports - 6 Control spool - 7 Control spring - 8 Return spring - 9 Plunger - 10 Housing -

11 Boring - 12 Rubber sleeve - 13 Lever.
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OPERATION PRINCIPLE PV4-5-2
(O/P)
PILOT VALVES EX135W

20° 20
0' '
28 ° 2
G D
B Pilot valve harness

B A B
G D A

Marrone
Bianco
Rosso

Grigio

Verde

Giallo
Nero

Blu
Connector
Bianco-giallo

Pilot valve hydraulic diagram

Rosso
Verde

Blu
Marrone
Nero

4 3
Control curve
T 5
bar
1 2
+6
24 0

P F3785
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Note - Maximum allowable

torque on control lever: 8 daNm.

6 -10

Plunger stroke
0 0,975 ±0,375
7,55 ±0,3 mm
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OPERATION PRINCIPLE PV4-5-3
(O/P)
PILOT VALVES EX135W

Left hand pilot valve

Solenoid Solenoid Solenoid Solenoid Arm

valve B1 valve B2 valve B3 valve A4

1 2 3
ON ON ON OFF OFF
Blade 1

2 4
Outrigger ON ON OFF OFF OFF
left

3
Outrigger ON ON OFF ON OFF
right

4
Horn – – – – – SX

Right hand pilot valve

Solenoid Solenoid Solenoid Solenoid Solenoid Travel

valve B3 valve B4 valve C1 valve C2 valve A5

5 6 7
Articulated ON ON – – – OFF 5
arm
8
6
Clamshell – – ON OFF – –
Left swing

7
Clamshell – – OFF ON – –
Right swing

8 DX
Hydraulic – – – – ON –
hammer
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Grass-cutter
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OPERATION PRINCIPLE PV4-5-4
(O/P)
PILOT VALVES EX135W

13 1
16 9

19
14 3
15 4

17
22
20

23 2
18 5

6
28 7
10 8

25
26

24
11
12

F7010
21599 60406991

1 Control lever - 2 Rubber sleeve - 3 Inner control lever - 4 Nut - 5 Threaded spacer - 6 Control plate - 7 Cardan joint
- 8 Plate - 9 Spring dowel - 10 O-ring -11 O-ring - 12 Screw - 13 Plunger guide - 14 Seal ring - 15 O-ring -
16 Plunger - 17 Needle - 18 Plate - 19 Control spring - 20 Return spring - 21 Shims - 22 Control spool - 23 Upper
housing - 24 O-ring - 25 Cylindrical pin - 26 Lower housing - 27 O-ring - 28 Screw.
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OPERATION PRINCIPLE PV4-5-5
(O/P)
PILOT VALVES EX135W

5.2 TRAVEL PILOT VALVE

5.2.1 OUTLINE

The travel pilot valve hydraulic device is a pedal controlled type and operates as direct - operated pressure
reducing valve.
Travel pilot valve basically consists of one operation pedal (4), a valve unit (two valves) and a housing (31).
Each pressure reducing valve consists of a control spool (29), a spring (27), and a plunger (25).
When is in non-operative condition, the pedal lever is kept in zero position by the spring (27).
Actuating the pedal lever (4), the plunger (25) at the same time pushed against the spring (27).

3
4
17
5

8
8
7 6
9 12

25 25
29 29
27
T
27 P
31 1
2
F7012
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1, 2 Ports - 3 Cover - 4 Pedal - 5 Pin - 6 Nut - 7 Screw - 8 Protection - 9 Support - 12 Screw - 17 Grub screw - 25
Plunger - 27 Control spring - 29 Control spool - 31 Upper housing.
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OPERATION PRINCIPLE PV4-5-6
(O/P)
PILOT VALVES EX135W

Travel pilot valve hydraulic diagram

P T

1 2

Note - Maximum allowable

torque on pedal control lever:
Control curve 20 daNm.

bar

+5
24 +0

-0
6 -1

mm Plunger stroke
0 0,85 5,0
F6966
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OPERATION PRINCIPLE CJ4-6-1
(O/P)
CENTER JOINT EX135W

6. CENTER JOINT

6.1 CENTER JOINT

6.1.1 GENERALITIES

The center joint is used to connect hydraulically and electrically the rotating portion of the turret to the
undercarriage (fixed portion).
The hydraulic fluid coming from the control valve or from the solenoid valves, enters the horizontal duct on
the outer sleeve (2), follows the circumference ducts, enters the vertical duct of the inner spindle (1) and
reaches the various actuators in the undercarriage.
Between one circumference duct and the next, Rotoglyd seals (7) are installed, to avoid leakages of oil from
one duct to the other.
The electrical portion installed in the upper part of the center joint includes a ten ring electrical collector allowing
the control of four solenoid valves located in the undercarriage and connecting the speed sensor and the
speed engagement micro switch with the APC50 control box.
The four valve involved by the electrical collector are:
• solenoid valve C2, controlling the travel motor displacement;
• solenoid valve C, clutch engagement;
• solenoid valve B, speed engagement;
• solenoid valve A, parking brake engagement.

16 15
17 15
7
6
8

4 5
3 1
2

13
14
14
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F9077

1 Inner spindle - 2 Outer sleeve - 3 Sealing flange - 4 Electrical collector support - 5 V seal - 6 O-ring - 7 Rotoglyd
seal - 8 Anti seizing ring - 13 Wire harness with four and six contact connectors - 14 Male connector - 15 Female
connector - 16 Nut - 17 Cover.
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OPERATION PRINCIPLE CJ4-6-2
(O/P)
CENTER JOINT EX135W

16

17

12

15
10
4
9
8
11

2
7

6
8
5
1

13

14
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F8942

1 Inner spindle - 2 Outer sleeve - 3 Sealing flange - 4 Electrical collector support - 5 V seal - 6 O-ring - 7 Rotoglyd
seal - 8 Anti seizing ring - 9 Countersunk head screw - 10 Cheese head screw - 11 Cheese head screw - 12 Ten
ring electrical collector - 13 Wire harness with four and six contact connectors - 14 Male connector - 15 Female
connector - 16 Nut - 17 Cover.
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DISASSEMBLY AND ASSEMBLY CJ4-6-1
(D/A)
CENTER JOINT EX135W

6.1 DISASSEMBLY AND ASSEMBLY OF CENTER JOINT

6.1.1 DISASSEMBLY

1 Loosen nuts (16), then pull-out the cover of electrical collector (17).

2 Loosen screws (10 and 9) to reach flange (3).

3 Loosen screws (11), then remove flange (3) and ring (8), to free the sleeve from the spindle.

4 Remove the electrical connections disconnecting the wires from the relevant plugs.

5 Connect a guide wire to the wiring to facilitate the installation at a later stage.

6 Using a universal puller, remove spindle (1) from sleeve (2) making sure that the electrical wires are not
damaged.

6.1.2 ASSEMBLY

1 Prior to proceeding with the reassembly, clean all components, ensuring that they are not damaged and
lubricate them with engine oil or grease.

2 Proceed with the operations, described for the disassembly phase, in a reversed order.

Note:
• Give your maximum attention in the installation of seals (7). Insert the O-ring in the relevant seat, then
proceed with the installation of the inner ring, deforming it as illustrated in the following figures A B C.
• To avoid damaging the seal, it is recommended that, during the installation, this part is not contacting sharp
edges or threaded surfaces. A slight lubrication facilitate the installation of the various components.
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B C

A
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DISASSEMBLY AND ASSEMBLY CJ4-6-2
(D/A)
CENTER JOINT EX135W

6.1.3 TIGHTENING TORQUES OF HYDRAULIC PIPES ON CENTER JOINT

Inlet System pipes Torque

1-2 Power steering 45 Nm
3 Draining 35 Nm
4-5 Travel motor 240 Nm
6-7 Stabilizers 45 Nm
8 Front axle brake 35 Nm
9 Rear axle brake 35 Nm
X Connection for travel motor/
10 stabilizers selector valve 45 Nm
solenoid valve
11 Axle lock 35 Nm
12 Transmission control 35 Nm
Left stabiliser
13 selector 35 Nm
solenoid valve

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OPERATION PRINCIPLE SV4-7-1
(O/P)
STEERING VALVE EX135W

7. STEERING VALVE

7.1 STEERING VALVE

7.1.1 DESCRIPTION

The steering unit consists of (see fig. 3):

- Metering and emergency hand pump that includes a gear wheel assembly with fixed stator (with inner teeth)
and a rotor (with outer teeth) (15).
- A 4 ways rotary distributor consisting of an outer sleeve (A) and an inner selection rotor (B).
The selection rotor is connected to the steering wheel, through column.
- A cardan shaft (11), mechanically tied to gear wheel assembly and to outer sleeve, allows the movement
transmission.
- Set of centering springs between outer sleeve and inner rotor.
- A relief valve (24-25) between the pump input and tank output ports.

Fig. 1 - Steering unit

103

2,8 83
A B

46
-+0,
82
ø 44,4
ø 25,4

L R
91
83
44

T P

min 7,1
7 29 44 L2 57°
L1 57
F8472

Dimensions

A = G. 1/2
B = 3/8-16 UNC
L1 = 139 mm
L2 = 20.8 mm
Weight = 5.6 kg
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Hydraulic connections

L - Left control port

R - Right control port
P - Inlet to steering pump
T - Outlet to hydraulic tank
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OPERATION PRINCIPLE SV4-7-2
(O/P)
STEERING VALVE EX135W

7.1.2 OPERATION

When the steering wheel is at standstill, (distributor is at neutral position), there is free flow through neutral
openings.
The oil passages to the control shaft are closed so that the shocks are not transmitted to the steering wheel.
Turning the steering wheel, the rotation of rotor (B) occurs. The ducts to the cylinder passages, gradually open
to the rotation of about 1.5°.
These ducts will completely opened at about 6°.
After about 4° of rotation, the neutral openings are closing.
The flow through the metering device takes place if the following conditions occur:
rotor rotation, oil volume supply directly proportional between steering wheel angular movement and control
cylinder displacement that produces the angular movement of the leading wheels.
The inside supply group from shaft to the outside sleeve of rotary distributor is in position so that the openings
are closing when the angular movement coincides with the steering wheel movement.
The supply group therefore, replaces the conventional mechanical linkage.

Fig. 2 - Steering unit hydraulic diagram

1
R

5 T To hydraulic
To steering tank
cylinder 200 +20 bar
-0 2
at 1 l/min. 140 +5 bar
-0
at 5 l/min.
6 5 P From steering
pump
L 3
4

1 - Steering unit
2 - Relief valve (set at 140 bar)
3 - Check valve
4 - Distributor
5 - Suction valve
6 - Shock valve (set at 200 bar)
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OPERATION PRINCIPLE SV4-7-3
(O/P)
STEERING VALVE EX135W

Fig. 3 3 4 20 16

13
16

12 22

18
1

7 9 (B) 2 (A) 11 14 15 15 17 21

26 2

26

1
27
29

25
24 2 5
7

3 8
4
9
11

2
13
14
12

15
21
16 22
17
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18

20

1 Dust seal ring - 2 Housing consisting of distributor with spool (B) and sleeve (A). Including check valve, seats for
dual shock valves and relief valve - 3 Ball - 4 Thread bushing - 5 Lip seal - 7 Bearing assembly - 8 Ring - 9 Cross
pin - 11 Cardan shaft - 12 Set of springs - 13 O-ring - 14 Distributor plate - 15 Gearwheel set - 16 O-ring -
17 End cover - 18 Washer - 20 Screw with pin - 21 Screw (Q.ty 6) - 22 Name plate - 24 Complete relief valve -
25 Spring wire - 26 Complete shock valve - 27 Ball - 29 Bushing with pin.
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OPERATION PRINCIPLE SV4-7-4
(O/P)
STEERING VALVE EX135W

7.1.3 ORBITROL TIMING

For precise keying and alignment of steering control valve, pay attention to the parallelism of A, B, C and D
reference marks.

Inner gear case

C
Drive

Pin Opening surface

F8473

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DISASSEMBLY AND ASSEMBLY SV4-7-1
(D/A)
STEERING VALVE EX135W

7.1 STEERING UNIT DISASSEMBLY AND ASSEMBLY

7.1.1 DISASSEMBLY

1 Dismantle steering column from steering unit and place

the steering unit in the holding tool. Screw out the screws
in the end cover (6-off plus one special screw).

2 Remove the end cover, sideways.

3 Lift the gearwheel set (with spacer if fitted) off the unit.
Take out the two O-rings.

4 Remove cardan shaft.

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DISASSEMBLY AND ASSEMBLY SV4-7-2
(D/A)
STEERING VALVE EX135W

5 Remove distributor plate.

6 Screw out the threaded bush over the check val-

ve.

7 Remove O-ring.

8 Shake out the check valve ball and suction valve

pins and balls.
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DISASSEMBLY AND ASSEMBLY SV4-7-3
(D/A)
STEERING VALVE EX135W

9 Take care to keep the cross pin in the sleeve

and spool horizontal. The pin can be seen
through the open end of the spool. Press the
spool inwards and the sleeve, ring, bearing races
and needle bearing will be pushed out of the
housing together.

10 Take ring, bearing races and needle bearing from

sleeve and spool. The outer (thin) bearing race
can sometimes "stick" in the housing, therefore
check that it has come out.

11 Press out the cross pin. Use the special screw

from the end cover.

12 Carefully press the spool out of the sleeve.

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DISASSEMBLY AND ASSEMBLY SV4-7-4
(D/A)
STEERING VALVE EX135W

13 Press the neutral position springs out of their slots

in the spool.

14 Remove dust seal and O-ring/kin-ring.

Dismantling the dual shock valves

15 Remove plugs from shock valves using a 6 mm

hexagon socket spaner.

16 Remove seal washers (2-off).

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DISASSEMBLY AND ASSEMBLY SV4-7-5
(D/A)
STEERING VALVE EX135W

17 Unscrew the setting screws using a 6 mm

hexagon socket spanner.

18 Shake out the two springs and two valve balls

into your hand. The valve seats are bonded into
the housing and cannot be removed.

19 The dual shock valves are now dismantled.

Dismantling the pressure relief valve

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20 Screw out the plug using an 8 mm hexagon

socket spanner. Remove seal washers.
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DISASSEMBLY AND ASSEMBLY SV4-7-6
(D/A)
STEERING VALVE EX135W

21 Unscrew the setting screw using an 6 mm

hexagon socket spanner.

22 Shake out spring and piston. The valve seat is

bonded into the housing and cannot be removed.

23 The pressure relief valve is now dismantled.

24 The steering unit is now completely dismantled.

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DISASSEMBLY AND ASSEMBLY SV4-7-7
(D/A)
STEERING VALVE EX135W

7.1.2 INSPECTION

Cleaning

Clean all parts carefully.

Inspection and replacement

Replace all seals and washers. Check all parts carefully and make any replacements necessary.

Lubrication

Before assembly, lubricate all parts with hydraulic oil.

7.1.3 ASSEMBLY

1 Place the two flat neutral position springs in the slot.

Place the curved springs between the flat ones and
press them into place.

2 Line up the spring set.

3 Guide the spool into the sleeve. Make sure that spool
and sleeve are placed correctly in relation to each other.
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DISASSEMBLY AND ASSEMBLY SV4-7-8
(D/A)
STEERING VALVE EX135W

4 Press the springs together and push the neutral

position springs into place in the sleeve.

5 Line up the springs and centre them.

6 Guide the ring down over the sleeve.

Note: The ring should be able to rotate free of

the springs.

7 Fit the cross pin into the spool/sleeve.

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DISASSEMBLY AND ASSEMBLY SV4-7-9
(D/A)
STEERING VALVE EX135W

8 Fit bearing races and needle bearing as shown

on below drawing.

Assembly pattern for roll bearing 1

1 - Outer bearing race

2 - Needle bearing 2
3 - Inner bearing race
3
4 - Spool ∗
5 - Sleeve

*The inside chamfer on the inner bearing race must

face the inner spool.

Installation instructions for O-ring/kin-ring

9 Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool
75301400 into the bore for the spool/sleeve.

10 Grease O-ring and kin-ring with hydraulic oil and

place them on the tool 75301400. Ø 28.36
O-ring and kin-ring Ø 25.4
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position on special
tool 75301400.
1.6

O-ring
Kin-ring
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DISASSEMBLY AND ASSEMBLY SV4-7-10
(D/A)
STEERING VALVE EX135W

11 Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide
the inner part of the tool right to the bottom.

12 Press and turn the O-ring/kin-ring into position in

the housing.

13 Draw the inner and outer parts of the assembly

tool out of the steering unit bore, leaving the gui-
de from the inner part in the bore.

14 With a light turning movement, guide the spool

and sleeve into the bore.

Note: Fit the spool set holding the cross pin

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horizontal.
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DISASSEMBLY AND ASSEMBLY SV4-7-11
(D/A)
STEERING VALVE EX135W

15 The spool set will push out the assembly tool

guide. The O-ring and kin-ring are now in position.

Installation instructions for O-ring/Rotoglyd-ring

9a Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool
75301401 into the bore for the spool/sleeve.

10a Grease O-ring and Rotoglyd-ring with hydraulic

oil and place them on the tool 75301401.

Ø 30.8

O-ring e Rotoglyd- Ø 25.4

ring position on
special tool
Rotoglyd-ring
75301401.
3.75

O-ring
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DISASSEMBLY AND ASSEMBLY SV4-7-12
(D/A)
STEERING VALVE EX135W

11a Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide
the inner part of the tool right to the bottom.

12a Press and turn the O-ring and Rotoglyd-ring into

position in the housing.

13a Draw the inner and outer parts of the assembly

tool out of the steering unit bore, leaving the gui-
de from the inner part in the bore.

14a With a light turning movement, guide the spool

and sleeve into the bore.

Note: Fit the spool set holding the cross pin

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horizontal.
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DISASSEMBLY AND ASSEMBLY SV4-7-13
(D/A)
STEERING VALVE EX135W

15a The spool set will push out the assembly tool
guide. The O-ring and Rotoglyd-ring are now in
position.

Assembly of check valve

16 Turn the steering unit until the bore is vertical

again. Put the check valve ball into the hole
identicated by the arrow.

17 Screw the threaded bush lightly into the check

valve bore. The top of the bush must lie just below
the surface of the housing.

Assembly of the two suction valves

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18 Place a ball in the two holes indicated by the

arrows.
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DISASSEMBLY AND ASSEMBLY SV4-7-14
(D/A)
STEERING VALVE EX135W

19 Place a pin in the same two holes.

20 Grease the O-ring with hydraulic oil.

21 Place the distributor plate so that the channel

holes match the holes in the housing.

22 Guide the cardan shaft down into the bore so

that the slot is parallel with the connection flange.
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DISASSEMBLY AND ASSEMBLY SV4-7-15
(D/A)
STEERING VALVE EX135W

23 Grease the two O-rings with hydraulic oil, and

place them in the two grooves in the gear rim.
Fit the gearwheel and rim on the cardan shaft.

24 Place the end cover in position.

25 Fit the special screw with washer and place it in

the hole where is located the Ø 8 mm ball.

26 Fit the six screws with washers and insert them.

Cross-tighten all the screws and the rolled pin
with a torque of 3.0 ± 0.6 daNm.
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DISASSEMBLY AND ASSEMBLY SV4-7-16
(D/A)
STEERING VALVE EX135W

Assembly of the pressure relief valve

27 Fit the piston.

28 Fit the spring.

29 Screw in the setting screw with a 6 mm hexagon

socket spanner. Make the pressure setting at 140
± 5 bar.

30 Screw plug with seal into the housing using an 8

mm hexagon socket spanner.
Tightening torque: 5 ± 1 daNm.
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DISASSEMBLY AND ASSEMBLY SV4-7-17
(D/A)
STEERING VALVE EX135W

31 Fit the dust seal ring in the housing using special

tool 75301402 and plastic hammer.

32 Press the plastic plugs into the connection ports.

Do not use a hammer.

Assembly of the dual shock valves

33 Put a ball in the two holes indicated by the arrows.

34 Place springs and valve cones over the two balls.

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DISASSEMBLY AND ASSEMBLY SV4-7-18
(D/A)
STEERING VALVE EX135W

35 Screw in the two setting screws using a 6 mm

hexagon socket spanner.
Make the pressure setting at 200 +20
-0 bar.

36 Screw plug with seal ring into the two shock

valves and tighten them with a torque of 3 daNm
using a 6 mm hexagon socket spanner.

Steering unit is now assembled.

7.1.4 SPECIAL TOOLS

ST NUMBER TOOL NAME Q.TY USE

75301400 O-ring + kin-ring assembly tool 1 To install the O-ring + kin-ring

75301401 O-ring + Rotoglyd-ring assembly 1 To install the O-ring + Rotoglyd-ring

tool

75301402 Dust seal ring assembly tool 1 To install the dust seal ring
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OPERATION PRINCIPLE BRV4-8-1
(O/P)
BRAKE PEDAL VALVE EX135W

8. BRAKE PEDAL VALVE

8.1 BRAKE PEDAL VALVE

8.1.1 DESCRIPTION

The brake pedal valve includes a single assembly, of small dimensions and easily adjusted, with a compact
and modular configuration.
The elements making the valve are assembled into a single device capable of ensuring full reliability under
all circumstances.
This braking system provides the possibility of using, with a limited amount of external connections, a small
portion of the energy of the hydraulic system of the machine, thus leaving the entire delivery of the system
available to other functions. This function is obtained through the charge valve, that gets automatically the oil
to charge the accumulators.
Its technical characteristics result in an increased braking power and a reduced effort on the pedal. The braking
pressure is regulated by modules connected to the braking circuits.

3 4 5

6
F11149

1 Service brake cylinder - 2 Pedal/support group - 3 First braking module - 4 Second braking module -
5 Accumulators charge valve - 6 Service brake control solenoid valve.

The brake pedal valve is made of elements assembled in a modular mode.

These elements are:
• Pedal/support group.
19400 60406991

• First braking module.

• Second braking module.
• Accumulators charge valve.
• Service brake cylinder.
• Service brake control solenoid valve.
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OPERATION PRINCIPLE BRV4-8-2
(O/P)
BRAKE PEDAL VALVE EX135W

Support/pedal group

The whole brake system is secured through the pedal/support group, to the floor plate of the machine.
This group regulates:
• the maximum braking pressure obtained through the rod stopping the stroke of the drive linkage;
• the angle of the pedal.

Braking modules

The braking modules are the elements controlling the braking pressure. Each braking module is connected
to a valve and an accumulator. The accumulators are high pressure type containers with a special membrane
subject, on one side, to the gas pressure, and to the oil pressure on the other. Three threaded outlets connect
the module to the brakes, the accumulator and the pressure switch controlling the stop lights.
The modules have longitudinal ducts allowing an hydraulic connection with the discharge and the charging
circuit of the accumulators.

Accumulators charge valve

The valve maintains the value of the pressure of the accumulators in a determined range (110 ÷ 140 bar). This
pressure is set by turning the screw located on the cylindrical end and is protected by a cap nut.

Service brake cylinder

The service brake cylinder controls hydraulically the braking modules. They actuate the service brakes
mounted on the front and rear axles at a pressure equal to the charge pressure of the brake accumulators.

Service brake control solenoid valve

The solenoid valve, of a cartridge type, is mounted on the cover of the accumulators charge valve. The service
brake control solenoid valve is actuated by the service brake actuating switch located in the cab. When
energised, it allows the passage of oil from the service accumulators to the service brake cylinder.

21599 60406991
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OPERATION PRINCIPLE BRV4-8-3
(O/P)
BRAKE PEDAL VALVE EX135W

8.1.2 OPERATION PRINCIPLE

The brake pedal valve controls the charge of the accumulators that are fed by the hydraulic power control
system, with a priority over other functions, through the accumulators charge valve. During the charge phase,
the charge valve acts as a distributor of differential delivery, ensuring the hydraulic supply to other functions
of the power control systems.
Once the charge pressure of the accumulator is reached, the charge valve directs the entire flow from the
pump to the subsequent functions.
The pressure in the accumulator circuit is maintained steady within the tolerance range of the charge valve.
The two service braking circuits are mutually protected through the check valves so that, in case of failures
of one the two circuits, the other operates perfectly.
The charge condition of the accumulator is monitored by the pressure switch so that the operator has a visual
signal in case of insufficient hydraulic pressure (i.e engine stoppage). Moreover, it signals, once the machine
is started, the efficient operation of the braking system.

Operation of the service braking system

When the service brake pedal is actuated, the two circuit braking valve regulates the pressure in the brake
cylinders according to the actuating force. The machine is slowed down by the action of the wheel brakes both
on the front and rear axles.
At the end of the braking phase, the oil returns into the reservoir.
In case of failure of one brake circuit, the second one remains in operating conditions through the mechanical
contact of the two braking valve plungers, ensuring the perfect functionality of the two accumulators. The
actuating force remains unchanged.
Every time the service brake is actuated, a pressure switch (set at 5 bar) monitors the pressure on the rear
axle brake circuit and energises the stop lights.

Operation of the service brake control solenoid valve

When the service brake button is actuated, the service brake control solenoid valve is energised and the
movement of the spool connects the accumulator charge pressure with the service brake actuating cylinder.
The stroke of the service brake control piston actuates the two brake modules that connect the accumulators
to the front and rear axle brake circuits.
When the service brake switch is actuated, the axle lock is automatically actuated.

10
11
16
17
2 R R R

F
14 9
12
X
Z
15 90 bar

6 70 bar T2 13 P

4
P
8
5 T1'
13
1
7 5 bar
B

70 bar T1
140 bar
70 bar

F8943
3
21599 60406991

1 Feeding to the systems - 2 Connection for service brake - 3 Discharge to the reservoir - 4 Connection for pressure
switch - 5 Stop lights pressure switch - 6 Delivery to front axle - 7 Delivery to rear axle - 8 Feeding to the pump - 9
Brakes system low pressure indicator pressure switch - 10 Service accumulator - 11 Carge accumulator -
12 Accumulators charge valve - 13 Brakes modules - 14 Service brake actuating solenoid valve - 15 Service brake
actuating cylinder - 16 Brake pedal - 17 Sensor.
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OPERATION PRINCIPLE BRV4-8-4
(O/P)
BRAKE PEDAL VALVE EX135W

8.1.3 SPECIFICATIONS AND DATA

Braking system ................................................................................................................................ type S6

Installation ..................................................................................................................................... horizontal
Diameter of brake valve modules ...................................................................................................... 14 mm
Braking circuits ............................................................................................................................................ 2
Diameter of service brake cylinder ..................................................................................................... 12 mm
Braking pressure ................................................................................................................................ 70 bar
Accumulator charge pressure .......................................................................................................... 110 bar
Maximum accumulator pressure ...................................................................................................... 140 bar
Nominal control voltage of solenoid valve ................................................................................... 27 Volt c.c.

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DISASSEMBLY AND ASSEMBLY BRV4-8-1
(D/A)
BRAKE PEDAL VALVE EX135W

8.1 MAINTENANCE

8.1.1 MAINTENANCE STANDARD

The precautions to be strictly observed during the assembly operations are listed here below.

• Connect all connections when the engine is inoperative and the system is not activated. For any operation
while the engine is running, check that the connections of discharge (N) and secondary supply (B) are open,
since severe damages to elements of the system and to persons could result if these connections are closed.

• Ensure that connections and lines are clean; foreign materials and dust into the system cause malfunctions
and wear.

• To bleed the air from the system, when the accumulators are charged and the engine is running, push the
brake pedal and open the bleeders for a few seconds.

• Insert the group from the bottom, after removing the side screw securing the pedal to the linkage.

• Help the filling of the feeding pump, bleeding the air from feeding connection (P) or an accumulator.

8.1.2 SETTING

Setting and testing of the accumulators pressure

With accumulators discharged, connect a pressure gauge (200 bar) to the brake pedal pressure gauge port.
Start the engine and push the pedal a few times, to cause the automatic charging, then read the pressure.
Adjust the pressure using the setting screw (protected by a cap nut) located on the accumulators charge valve
body. The max. charge pressure of the accumulators must be 140 bar.

Setting of the brake pressure

Connect a pressure gauge (200 bar) to one brake circuit and actuate the brakes. The pressure is related to
the stroke of the pedal.
The braking pressure is adjusted by the setting screw located under the pedal.
The max. pressure to be sent to the pistons is 70 bar.

Setting of pedal angle

Loosen the side screw of the pedal and adjust the angle using the threaded dowel underneath. Lock dowel
and screw in the desired position.
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DISASSEMBLY AND ASSEMBLY BRV4-8-2
(D/A)
BRAKE PEDAL VALVE EX135W

8.1.3 PRESSURE SWITCHES

Generalities

They include a monitoring element made of an oil resistant membrane, silver plated electric contacts, body
with faston connections, balance and setting springs of the pressure to be monitored.
For the setting of the pressure to be monitored, it is necessary to procure a small screwdriver and actuate the
setting screw (V), taking care that the spring is not totally pressed.
The electrical connection and the internal elements are protected against moisture or dust by a protection
boot.
V

Specifications and data

Setting of pressure switch (1) ............................................................................................................ 90 bar

Setting of pressure switch (2) .............................................................................................................. 5 bar

2
19400 60406991

F11167

1 Brake system low pressure indicator pressure switch (90 bar) - 2 Stop lights pressure switch (5 bar).
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OPERATION PRINCIPLE ACC4-9-1
(O/P)
ACCUMULATORS EX135W

9. ACCUMULATORS

9.1 ACCUMULATORS

9.1.1 GENERALITIES

Four accumulators (three for the brake system and one for the power controls) are mounted on the turret.
Functionally, the accumulators are identical, of a membrane type, and ensure a certain number of actutions
of the systems they are connected with, in case of lack of hydraulic pressure.
The membrane type accumulator includes a pressure resistant steel container, mounting inside, as a
separation element, a membrane made of elastic material. The membrane is secured by a ring nut between
the lower and upper portion of the body.
In the central lower part of the membrane, a metal disc is incorporated, preventing its exit from the fluid inlet
port.

1 - Gas valve
3 2 - Container
3 - Membrane
4 4 - Valve head
5 - Oil side mounting
5

When no hydraulic pressure is present, the membrane, loaded on the gas side by the pre-load pressure (P0)
leans against the inner surface of the accumulator and the head closes the fluid flow. When hydraulic pressure
is applied, the pre-load pressure is overcome compressing the nitrogen, and the head is lifted, thus the fluid
enters the accumulator.
The quantity of useful oil results from the difference between the volume of gas and the minimum and
maximum operating pressure.

P0 P1 P2
V0 V1 V2
∆V
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OPERATION PRINCIPLE ACC4-9-2
(O/P)
ACCUMULATORS EX135W

9.1.2 MAINTENANCE

Testing or reduction of pressure

To perform this operation it is necessary to provide a hose. Discharge the pressure in the pump circuit, remove
or isolate the accumulator, remove the protection cap of the pre-charge valve on the shockless device, install
the pre-charge device tightening ring nut (1) on the accumulator valve.
Screw, without tightening it, handle (4) and read the charge pressure on pressure gauge (3); if it is too high,
open slightly discharge valve (2).
Unscrew handle (4), remove the re-charge device, re-install the protection cap on the accumulator valve.

Increasing the charge pressure

To pre-charge or to increase the pre-charge pressure, remove the protection cap of the valve on the shockless
device, install the pre-charge device, turning ring nut (1), leaving handle (4) unscrewed and tighten completely
discharge valve (2).
Remove cap (5) and connect hose (6) to a bottle of nitrogen. Tighten, without forcing, handle (4) and open
slowly the nitrogen bottle.
While reading pressure gauge (3) increase the pre-charge pressure until a value slightly over the desired value
is obtained.
Loosen handle (4), close the bottle valve, empty hose (6) opening and closing valve (2) and wait for a few
minutes.
Tighten handle (4) and read the pressure; if it is correct, unscrew handle (4) and remove hose (6), unscrewing
ring nut (1). If it is not correct, increase or reduce the pressure, as indicated above.

Note - For the pre-charge, nitrogen only must be used.

2 3 4 5 6 7

1
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Accumulator Nitrogen bottle

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OPERATION PRINCIPLE ACC4-9-3
(O/P)
ACCUMULATORS EX135W

9.1.3 SPECIFICATIONS AND DATA

Power system accumulator

Nominal capacity................................................................................................................................ 0.75 ltr
Pre-charge pressure ............................................................................................................................ 8 bar
Weight .................................................................................................................................................... 2 kg

Brake system accumulators

Nominal capacity................................................................................................................................ 0.35 ltr
Pre-charge pressure .......................................................................................................................... 50 bar
Weight .................................................................................................................................................... 2 kg
21599 60406991
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OPERATION PRINCIPLE ACC4-9-4
(O/P)
ACCUMULATORS EX135W

NOTES:

21599 60406991
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DISASSEMBLY AND ASSEMBLY ACC4-9-1
(D/A)
ACCUMULATORS EX135W

9.1 DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR

1 Discharge the pressure from the system

2 Ensure that the accumulator is totally empty of gas using the testing/inflating device. If the latter is not
available, push the sealing valve with a screwdriver until no more gas is flowing out.

3 Loosen and remove the re-charge valve assembly.

4 Loosen the upper cap with a filter type wrench.

5 Pull-out the membrane.

6 Clean thoroughly the inside of the accumulator.

7 Smear the seat for the new membrane with grease.

8 Install a new membrane.

9 Replace the O-ring with a new one.

10 Tighten strongly the upper cap.

11 Install a new charge valve.

12 Bring the accumulator to the pressure desired, using the pre-charge device.

ATTENTION
Do not use any gas besides NITROGEN Danger of explosion.

Warning
Before testing the pre-charge or changing the pressure, ensure that the accumulator is totally discharged on
the fluid side.
In case of replacement of the membrane, wet the walls with the fluid pumped or with a compatible one to
facilitate the adherence of the new membrane.
Before installing the accumulator, ensure that:
• the data etched on the body are compatible with the specifications of the system;
• the pre-charge pressure corresponds to the required value.
• An incorrect pre-charge pressure, besides causing a bad operation of the system, can impair the life of the
membrane or bag. The value of the pre-charge is related to a 20°C temperature.
21599 60406991
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DISASSEMBLY AND ASSEMBLY ACC4-9-2
(D/A)
ACCUMULATORS EX135W

NOTES:

21599 60406991
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OPERATION PRINCIPLE SOV4-10-1
(O/P)
SOLENOID VALVES EX135W

10. SOLENOID VALVES

10.1 SELECTOR SOLENOID VALVES

10.1.1 GENERALITIES

The solenoid valves are located in the lower side of the turret, on the cab side. Their function is to divert the
oil flow coming from the hand pilot valve and the pedal pilot valve toward the actuator lines, such as: digging
control line and blade/stabilisers line; travel control line and positioner arm line.

10.1.2 CONSTRUCTION

The four selector solenoid valves (Fig. 1) are mounted on two bodies (two per body).

Fig. 1 - Selector solenoid valve

1
2

F3786

1 - Body
2 - Solenoid valves
21599 60406991
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OPERATION PRINCIPLE SOV4-10-2
(O/P)
SOLENOID VALVES EX135W

Please find, herebelow, the inner hydraulic diagram of the selector solenoid valves assembly, the
connections with the general hydraulic system and the functions of the relevant solenoid valves.

Fig. 2 - Selector solenoid valves assembly and hydraulic diagram

2
C A
1
P2 P1

D B

F3787

1 - Body
2 - Selector solenoid valves

Solenoid valves B1
21599 60406991

Solenoid valves B3

F3789
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OPERATION PRINCIPLE SOV4-10-3
(O/P)
SOLENOID VALVES EX135W

Connections to the general hydraulic system (see Fig. 2)

Digging and blade/stabilisers selector solenoid valve (B1-B2):

- P1 Pilot system pressure inlet from left pilot valve (*);
- P2 Pilot system pressure inlet from right pilot valve (*);
- A To control valve, blade/stabilisers section (*);
- B To control valve, digging control section (*);
- C To control valve, blade/stabilisers section (*);
- D To control valve, digging control (*);

Travel and positioner arm selector solenoid valves (B3-B4):

- P1 Pilot system pressure inlet from pedal pilot valve (*);
- P2 Pilot system pressure inlet from pedal pilot valve (*);
- A To control valve, positioner arm section (*);
- B To control valve, travel control section (*);
- C To control valve, positioner arm section (*);
- D To control valve, travel control end kick down pressure switch (*);

(*) G. 1/8

Solenoid valve functions (see Fig. 2)

Digging and blade/stabilisers selector solenoid valves (B1-B2):

The two solenoid valves are connected in parallel. In rest conditions, they allow the hydraulic feeding of the
digging line; when they are energised, they allow the hydraulic feeding of the blade/stabilisers line.

Travel and positioner arm solenoid valves (B3-B4):

The two solenoid valves are connected in parallel. In rest conditions, they allow the hydraulic feeding of the
travel line; when they are energised, they allow the hydraulic feeding of the positioner arm line.
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OPERATION PRINCIPLE SOV4-10-4
(O/P)
SOLENOID VALVES EX135W

10.2 SERVICES SOLENOID VALVES GROUP

10.2.1 GENERALITIES

The services solenoid valves group is located in the turret in the air cleaner and hydraulic pumps
compartment. Its function is to allow, through solenoid valves, the delivery of piloting oil to the relevant
actuators mounted on the machine.

10.2.2 CONSTRUCTION

The services solenoid valves group (see Fig. 1) is made of a body, six solenoid valves and a pilot system
pressure relief valve.

Fig. 1 - Services solenoid valves group

2
2
2

2
2
2
3

1 F7011
2

21599 60406991

1 - Body
2 - Solenoid valves
3 - Pilot system pressure relief valve
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OPERATION PRINCIPLE SOV4-10-5
(O/P)
SOLENOID VALVES EX135W

Herebelow, please find the internal hydraulic diagram of the services solenoid valve group, the connections
with the main hydraulic system, the functions of the pressure relief valve and the relevant solenoid valves.

Fig. 2 - Services solenoid valves group assembly and hydraulic diagram

3
3 3
3 3
3
2

T
P1 T1
A1 A3 A4 A5 A6

A2
P

4
1

A0
A1 A2 A3 A4 A5 A6

4
3 3 3 3 3 3
21599 60406991

F8944

1 Services solenoid valves group body - 2 Pilot system pressure relief valve - 3 Three way solenoid valves A1 - A2
- A3 - A4 - A5 - 4 Two way solenoid valve A0.
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OPERATION PRINCIPLE SOV4-10-6
(O/P)
SOLENOID VALVES EX135W

Connections to the main hydraulic system (see Fig. 2)

-P Pilot system pressure inlet (*),

- P1 Outlet for pedal pilot valve (*);
-T Hydraulic reservoir outlet (**);
- T1 To diverter block (**);
- A1 To diverter block (**);
- A2 To axle lock valve (**);
- A3 To blade/stabiliser/travel motor selector valve (**);
- A4 To left/right stabilisers selector valve (**);
- A5 To hammer control valve (**).
- A6 To grass-cutter control valve (**).

(*) 1/4 in Gas connections (**) 1/8 in Gas connections

Functions of solenoid valves (see Fig. 2)

- A0 Parking brake and travel control cut-off solenoid valve.

Two way, two position, normally closed solenoid valve. It feeds the pedal controlling the travel or positioner
arm, depending upon the rest or energised state of the travel/positioner arm selector solenoid valves. This
solenoid valve is energised by the parking brake selector and, under these conditions, inhibits the travel
control.

- A1 Pilot valves neutralizer solenoid valve (pilot system cut-off).

Three way, two position, normally closed solenoid valve. It feeds, through a diverter block, the single lever
pilot valves controlling boom, bucket, swing, dipper stick and blade and/or side stabilisers, depending upon
the rest/energised state of the dipper stick/blade/stabilisers selector solenoid valve. When the electric
circuit is set ON by the starter key, the solenoid valve is positioned in open and remains in this position as
long as the electric circuit is not cut-off voluntarily by lifting the left arm rest mounting the pilot valve and
its switch installed at its end, or by actuating the safety switch for road travel located on the steering column.

- A2 Axle lock valve control solenoid valve.

Three way, two position, normally closed solenoid valve. If energised, it moves to open position and allows
the piloting oil to pilot the locking of the front axle. Under rest conditions, the hydraulic system is cut-off,
thus the axle lock valve, normally closed, intercepts the hydraulic connection between the two locking
cylinders.

- A3 Travel speed shift control solenoid valve and blade/stabilisers selector valve control solenoid
valve.
Three way, two position, normally closed solenoid valve. If actuated, it sends the piloting oil to the regulator
of the travel hydraulic motor regulator to keep it at maximum displacement (slow travel speed = TURTLE).
With the valve in rest condition, the regulator is connected to the reservoir (normal travel speed = RABBIT).
The same solenoid valve allows also the operation of the blade/side stabilisers.

- A4 Left/right side stabilisers selector valve control solenoid valve.

Three way, two position normally closed solenoid valve, If actuated, it sends piloting oil to the left/right side
stabiliser selector valve.

- A5 Hammer valve control solenoid valve.

Three way, two position, normally closed solenoid valve. If actuated, it sends piloting oil to the hammer
valve.
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OPERATION PRINCIPLE SOV4-10-7
(O/P)
SOLENOID VALVES EX135W

- A6 Grass-cutter control solenoid valve.

3-way and 2-position solenoid valve, normally closed. If activated, it sends the oil to the grass-cutter valve.

Components of solenoid valve.

Each solenoid valve is made of a body 1 (Fig. 3), control valve (2), coil (3), connection (5).

Fig. 3 - Components of solenoid valves

3 4 3 4 3 4

3 4

5
5
2

1
F8945

1 Body - 2 Control valve - 3 Coil - 4 Diode - 5 Connection.

Solenoid valve connector diode

The electrical energizing of the solenoid valves causes current peaks that could damage electrical and
electronic components installed on the machine. To avoid the problem, a diode (6) is mounted inside the
21599 60406991

solenoid (4), between the positive wire and the negative of each solenoid.
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OPERATION PRINCIPLE SOV4-10-8
(O/P)
SOLENOID VALVES EX135W

Pilot system pressure relief valve

Generalities

The valve has the function of maintaining the pressure value of the oil inside the solenoid valves group at
35 ± 3 bar. In case the pressure exceeds its value, the valve operates discharging the excess into the return
line to the reservoir.

Operation
The internal operation of the valve is as follows (Fig. 4):
- The pressure existing in duct (P) acts on plunger (7) through orifice (8) on the spring loaded side of the
plunger itself and, through nozzle (10) on cone (5) pushed by spring (3).
If the pressure in duct (P) exceeds the setting value of spring (3) cone (5) moves and allows the oil to flow-
out through discharge ducts (9) connected to discharge (T). With this movement, a pressure drop occurs
on plunger (7) that will move under the action of the hydraulic pressure in duct (P) not charged any more.
The movement of plunger (7) will connect duct (P) with duct (T) until the pre-set pressure is re-established.

Fig. 4 - Sectional view of pilot system pressure relief valve

1 2 11 3 4 5 12 6 9 7 13 14

8
T

10 9
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1 Cover - 2 Setting screw - 3 Setting spring - 4 Body - 5 Cone - 6 Plunger spring - 7 Plunger - 8 Orifice -
9 Discharge duct - 10 Nozzle - 11 Washer - 12 O-Ring - 13 Back-up ring - 14 O-Ring - P Oil inlet - T Oil discharge
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PRINCIPIO DI FUNZIONAMENTO PRV4-11-1
(O/P)
PRIORITY VALVE EX135W

11. PRIORITY VALVE

11.1 PRIORITY VALVE

11.1.1 GENERALITIES

The priority valve is located on the side of the hydraulic oil reservoir in the hydraulic pumps compartment,
Its function is to ensure a constant delivery to the pilot system line entering the services solenoid valves
group and the transmission control solenoid valves.

11.1.2 CONSTRUCTION

The priority valve (see Fig.1) is made of a body on which a delivery regulation valve is mounted.

Fig.1 - Priority valve assembly

1
M
2

C
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F7456

1 - Body
2 - Delivery regulation valve
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OPERATION PRINCIPLE PRV4-11-2
(O/P)
PRIORITY VALVE EX135W

Connections to the general hydraulic system (see Fig. 2)

- A (3) To the pilot system, the services solenoid valves group and, through a T joint, to the accumulator and
the transmission control solenoid valves group, located in the undercarriage;
- B (2) Secondary line connecting solenoid valve C1 controlling the rotary bucket;
- P (1) Pilot system pressure inlet coming from the brake pedal valves group.
- C (4) Gear box control valve pressure inlet.
- M (5) Power take-off inlet.

Fig. 2 - Hydraulic diagram

3
5

4
2

F7013
1

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INDEX EX135W - 5 - 1

SECTION 5 UNDERCARRIAGE

INDEX

Group 1 - UNDERCARRIAGE ...................................................................................... UC5-1-1

1.1 Outlines
1.2 Lower frame
1.3 Swing bearing
1.4 Travel unit
1.5 Wheels
1.6 Blade assembly
1.7 Lateral stabilizers
1.8 Hydraulic hoses and undercarriage components

Group 2 - TRAVEL HYDRAULIC MOTOR - O/P - D/A ............................................... HYM5-2-1

2.1 Travel hydraulic motor - O/P

2.1 Disassembly and assembly - D/A

Group 3 - TRANSMISSION - O/P - D/A ......................................................................... TM5-3-1

3.1 Transmission - O/P

3.1 Transmission assembly and disassembly - D/A
3.2 Gear unit broken, insertion of 1st gear to finish work - D/A
3.3 Specific tools - D/A
21599 60406991

O/P - OPERATION PRINCIPLE (continued)

D/A - DISASSEMBLY AND ASSEMBLY
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INDEX EX135W - 5 - 2
INDEX (continued)

Group 4 - AXLES - O/P - D/A ........................................................................................ AX5-4-1

4.1 Rear axle - O/P

4.2 Front axle - O/P
4.3 Braking unit - O/P
4.1 Dissassembly and assembly of axles - D/A

Group 5 - TRANSMISSION SHAFT - O/P - D/A ............................................................ TS5-5-1

5.1 Transmission shaft - O/P

5.1 Disassembly and assembly - D/A

O/P - OPERATION PRINCIPLE

D/A - DISASSEMBLY AND ASSEMBLY

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UC5-1-1

UNDERCARRIAGE EX135W

1. UNDERCARRIAGE

1.1 OUTLINES

The undercarriage is composed of the following standard parts:

1 - Lower frame
2 - Swing bearing
3 - Travel assembly
4 - Wheels

In addition the undercarriage can be fitted with:

- Blade
- Lateral stabilizers

1
2
4

F7472

3
4
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4
4
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UC5-1-2

UNDERCARRIAGE EX135W

1.2 LOWER FRAME

1.2.1 DESCRIPTION

The lower frame assembly consists of a single welded element. The joint between the lower frame and the
upperstructure is carried out by means of a swing bearing that, moreover, allows the swing of upperstructure.
Ladders and tools box are fixed on the sides of lower frame.

2
5
1
4
3

F6967

3
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1 - Lower frame
2 - Swing bearing
3 - Ladders
4 - Tools box
5 - Parking wedges
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UC5-1-3

UNDERCARRIAGE EX135W

1.3 SWING BEARING

1.3.1 DESCRIPTION

The swing bearing consists of an outer race (3) bolted to the upperstructure, an inner race (2) bolted to the
lower frame and a double rows of balls (4).
The swing reduction pinion (8), controlled by swing motor through the swing reduction gears, rotates on its
own axis and it also revolves round the centre of inner race of swing bearing, allowing the upperstructure to
swing independently of the lower frame.

11 3
4
12
2
8
9

10

1- Lower frame 7 - Platform

2- Inner race 8 - Swing reduction pinion
3- Outer race 9 - Outer race screw
4- Bearing ball 10 - Inner race screw
5- Inner seal 11 - Seal
6- Outer seal 12 - Grease nipple
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UNDERCARRIAGE EX135W

1.3.2 DATA

Dimensions

Ø 1195

Ø 1160

Ø 1080
96

Ø 939

Ø P. 960
Ø 1040

Ø 1098

Maximum trust clearance ............................................................................................................... 0.35 mm

Maximum radial clearance. ............................................................................................................. 0.35 mm

Teeth

Module ...................................................................................................................................................... 12
Number of teeth ........................................................................................................................................ 80
Pressure angle ........................................................................................................................................ 20°
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UNDERCARRIAGE EX135W

1.3.3 MAINTENANCE

(1) Preliminary operations:

- Remove the counterweight (see section 4, Upperstructure).
- Remove the front attachment (see section 6, Front attachment).
- Remove the upperstructure (see section 4, Upperstructure).

(2) Removal operations:

- Remove the inner race fixing screws.
- Install three eyebolts placing them to 120° on the swing bearing circle.
- Uplift the swing bearing by means of hoist.
Note : The weight of swing bearing is 195 Kg.

(3) Installation operations:

- Place the complete swing bearing assembly on lower frame.
- Tighten the screws on the inner race.
Tightening torque 34 ± 3 daNm
- Position the upperstructure platform aligning the screw holes on outer race with the screw holes on
the platform.
- Install and tighten the screws.
Tightening torque 34 ± 3 daNm
- Complete the assembly by fixing the upperstructure, and installing the front attachment and
counterweight (see section 6, Front attachment and section 4, Upperstructure).

(4) Note for installation

- The races on which the steel balls run, are induction hardened.
On the inner race (inside gear side) the soft zone is marked with “S”. To minimize the load on this
zone, the side marked “S” must be positioned on the right side of the frame, as illustrated here below.
Also the outer race has a soft zone near to the ball filler port, that must be positioned toward the right
side, as illustrated.
- Every time the swing bearing is installed, do not re-use the old screws but replace them with new
screws.

1 2
21599 60406991

1 - Soft zone of outer race

2 - Soft zone of inner race
3 - Ball filler port.
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UNDERCARRIAGE EX135W

1.4 TRAVEL UNIT

1.4.1 DESCRIPTION

The travel unit includes: an hydraulic motor (1), a transmission unit (2), drive shaft (3), rear axle (4), front axle
(5).

3
1
2
4
F7471
5
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UNDERCARRIAGE EX135W

1.5 WHEELS

1.5.1 DESCRIPTION

The wheels adopted can be both in twin and in individual assembly.

- For twin assembly, conventional tyres are used (1).
- For individual assembly, radial tyres are used (2).

The adoption of these tyres assures the best performance for each application. None of these choices is
absolutely the best but each of them offers particular advantages to be considered when choosing the suitable
tyre for a special kind of work.

1 - Conventional type
twin tyres 10.00 x 20 EM NB-38 16 PR MITAS ................................... Inflation pressure 7.5 bar
twin tyres 10.00 x 20 EM NB-38 14 PR MITAS ................................... Inflation pressure 6.5 bar

2 - Conventional type
individual tyre 600/40 - 22.5 ALLIANCE ................................................ Inflation pressure 6 bar

3 - Radial type
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individual tyre 18R - 19.5 MICHELIN ..................................................... Inflation pressure 7 bar

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UNDERCARRIAGE EX135W

- Each wheel, used for individual tyre assembly, is composed of: tyre, rim, inflation valve.
The tyre is radial type and the rim is drop centre type.
The four wheels use the same rims and tyres but the tread pattern is oriented according to the travel direction.
Therefore there are two kind of wheel assemblies, two for left side and two for right side installation.

Tyre bead base

Inflation valve seat Disc

Rim for individual tyre assembly

- Each wheel, used for twin tyres assembly, is composed of: tyre, rim , inner tube and inflation valve.
The tyre is conventional type and the rim is flat, demountable rings (three piece) type with a locking ring and
conical base side ring.
The rims are different in relation with their installation position on the machine. The rim for outer wheels
installation has an offset of the disc bigger than the disc offset of the inner wheel rim.
The tyres are the same but the tread pattern are oriented according to the travel direction.
Therefore there are two inner wheels and two outer wheels assemblies for left side and two inner wheels and
two outer wheels assemblies for right side installation.
In the cavity between outer and inner wheel a rubber ring (1) is installed to avoid the soil and stones keeping.

Side ring with

conical base
Locking ring

Disc Flat rim

Offset
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1 - Spacer rubber ring

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UNDERCARRIAGE EX135W

Valve
Each rim is equipped with an inflation valve.

valve seat

sealing ring
rim

nut
valve sealing
valve cover

tightening elbow valve

On above is shown a rim section of a wheel. This rim installs an elbow valve screwed to feasible the tyre
inflation.
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UNDERCARRIAGE EX135W

1.5.2 CONVENTIONAL TYRES

Conventional tyres are used in most applications due to the continuous improvements in the resistance
characteristics of synthetic yarns, used in housing manufacture. Each string of every ply, with an angle of
about 60°, runs from a bead to the other. The subsequent plies cross opposed angles among the string.
The higher the number of piles, the higher the load that the tyre can stand.
The max. load a conventional tyres can stand, is given by PR (ply rating) number, a theoretical number which
must not be confused with the real number of plies, usually lower. PR is considered the index of tyre load
capacity.
Conventional tyres, being manufactured with different kinds of compounds, can stand higher temperatures
(110° C) than radial tyres but they hold the heat longer, due to the high tickness of housing plies.

Advantages of conventional tyres

- Max. side protection of housing on side.

- Easy repair and remanufacture.
- Low costs per hour
- Excellent resistance to sudden changes of temperature.
- High side stability.
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UNDERCARRIAGE EX135W

1.5.3 RADIAL TYRES

The housing of radial tyres has two main parts both manufactured with steel strings. In the radial tyre a strings
ply goes from a bead to the other forming the side strength element. The steel strings form a right angle with
the tyre middle plane; in conventional tyres this angle was acute.
The difference in the strings and individual ply manufacture guarantee to the radial type a higher vertical
flexibility. This is an advantage for the sides but not for the tread. Therefore, the second main component of
the radial tyre is the belt wrapping the housing below the tread. The belt, formed by overlapped plies in steel
string, increase the contact area and the tread resistance. The radial tyre is better for traction and floatage.
Due to the special adhesive substances used to adhere rubber to steel, the limit temperature these tyres can
reach is lower than the one of conventional tyres (about 93°C). However radial tyres, due to the lighter
structure and the better thermal conductivity of steel, eliminate heat more easily and can operate at higher
speeds.

Advantages of radial tyres

- Higher works speeds.

- Higher floating.
- Higher traction.
- Higher penetration-resistance.
- Lower roller resistance.
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UNDERCARRIAGE EX135W

1.5.4 PRECAUTIONS TYRES INFLATION

- During inflation, tyres can undergo an explosive disjunction, possible to generate serious injuries.
- Before tyres inflation, always check rims conditions and tyres outer conditions for the presence of dents,
cuts, reinforcement plies tearing and other faults.
- It is recommended that checks and maintenance are carried out by a specialized technician.
- Inflate by using a protection cage and a tyre inflation gun with extension complete with checking pressure
gauge.
- Before start the inflation, make sure no people is nearby and stay on the track side or outer belt.
- Never exceed the prescribed pressures for the single types of tyres and always check for equal pressures
between right hand tyre and the correspondent left hand tyre.

Inflation standard pressure :

Conventional tyre twin 10.00 x 20 EM NB-38 type 16 PR MITAS = 7.5 bar
Conventional tyre twin 10.00 x 20 EM NB-38 type 14 PR MITAS = 6.5 bar
Radial tyre individual 600/40 - 22.5 ALLIANCE type = 6 bar
Elements which may give a correction of the standard pressures:
- Overload.
- Run shape.
- Need for “floating”, that is improvement of rolling attitude on insubstantial bottoms.
- Room temperature.
The prescribed pressure is related to cold tyres.
If it could not feasible to detect the pressure in those conditions, it will be necessary to use a suitable correction
factor.

a) Temperature higher than 25 °C

(pressure taken outside, in the yard)
- from 25 to 29 °C ................................................................................................. increase pressure by 4 %
- from 30 to 34 °C ................................................................................................. increase pressure by 6 %
- from 35 to 39 °C ................................................................................................. increase pressure by 8 %
- from 40 to 45 °C ............................................................................................... increase pressure by 10 %
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b) Room temperature lower to 0 °C

The use of low temperature tyres ( < 0°C) implies an increase of the base pressures depending on the
room temperature in yards and, in case of uses at rather low temperatures, it may need special precautions.
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UNDERCARRIAGE EX135W

1.5.5 TYRES UTILIZATION RULES

Pressure

The use of tyres at the right pressure and its continuous check are one of the best and more efficient rules
to obtain the best performances and the longest life of tyres.
On the contrary, the use of non suitable pressures is a great contribution to the early breakages. A great
amount of damages - both to the structure and to the tyres lugs - may be avoided with a continuous check of
inflating. A too low a pressure may damage the textile structure of the tyre; the continuous and abnormal flexion
of flanks can cause cuttings and separation in the manufacture.
An extreme inflation must be avoided as well because it may lead to anomalous wears and even the structure
breakage. We remind you that the pressure must be determined considering the total load on the machine,
included possible accessory equipment.
Anyway, the tyre pressure must never exceed the max. values indicated for the dimension in subject. It is good
to check inflation monthly with a reliable tool. Fit the caps on the valves to prevent air losses.

Use on the road

The tyres have been designed to work on the fields where the transverse rods penetrate the soil and every
part of the track gets in contact with it. The running on hard or asphalted surface causes the tyre distortion
and the rods bend extremely when getting in contact with the ground and are loaded by the weight.
On hard soils, the result of all this is that the tyre is “grated” away by this movement and an early and irregular
wear is created.
For the road running it is recommended to increase tyres inflation, within the max. limits for the dimension in
subject; this allows to reduce the rods movement, the reason of the anomalous wear.
In these conditions, however, the wear in the centre of the tread is greater.

Repairs

Check the condition of your tyres periodically, mainly during wet seasons.
Humidity is not good for tyres. Cuts on the tread or flanks reaching the strings are a way of access for humidity
and foreign materials which make the tyre structure unserviceable.
A tyre with the above damages must be carefully and immediately repaired by competent staff.
If only the rubber part is concerned in the damage, without touching the structure, it is important to avoid that
stones and foreign materials can get inside.
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UNDERCARRIAGE EX135W

1.5.6 TWIN WHEELS DISASSEMBLY AND

ASSEMBLY

Disassembly

1 Raise the machine from the side where

you need to remove the wheels.
Raise the wheel about 10 cm (4 in) with
the help of the front attachment and hold
machine with proper device.

WARNING
Before operating, deflate outer tyre (inner ring
kept tight by the pressure of the two twin tyres
is now free).

2 Remove the two inflating valves from the

special fork.

3 Untighten the nuts of the stud bolts.

4 Be care to the coming out of the inflating

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valve extension.
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UNDERCARRIAGE EX135W

5 Remove the outer wheel.

6 Remove the space rubber ring.

7 Remove the inner wheel.

Note: Check the stud bolts.

If, one or more stud bolts should be
replaced, for safety reason all the stud
bolts set of the wheel must be replaced,
because even the remaining bolts will be
surely damaged.
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UNDERCARRIAGE EX135W

Assembly

CAUTION
Before installing the wheel check that tyre
tread is oriented according to the travel direction
of the machine.

Note: For an easy assembly it is advisable to

fit the wheel with tyres partially inflated.

1 Install the inner wheel.

Match the rim surface with the axle hub
centering base.

Lock the inner rim to avoid its movement.

Note : The inner rim has the shorter disc

offset.

2 Insert the rubber spacer ring.

Note: For a good working and a longer

tyre life, centre the spacer on the tyre.

3 Fit outer wheel checking that the inflating

valve of the inner tyre comes out of the
outer rim holes.
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WARNING
Two hub studs are longer. They are used to
center the spacer.

Note: The outer rim has the greater disc

offset.
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UNDERCARRIAGE EX135W

4 Tighten the rim fixing nuts on the wheel hub.

Tightening torque = 50 to 60 daNm

5 Insert the two inflating valves into the suitable

fork.

6 Inflate the tyres to the foreseen values.

Inflation pressure:
Conventional tyre,
twin 10.00 x 20 14 PR type = 6.5 bar
Radial tyre,
individual 600/40 x 22.5 type = 6 bar

7 Lowering the machine to the ground having

it supported on the tyres.
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Note: About 2 hours of travelling after a wheel

reinstallation, check again the nuts tightening
torque.
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UNDERCARRIAGE EX135W

1.5.7 TYRE DISASSEMBLY AND ASSEMBLY

Disassembly

For tyre disassembly first deflate it completely, untightening the valve mechanism.
With a tool and a hard hammer, detach the bead from the flange. Be careful not to damage neither the tyre
nor the rim. Detach the first bead, turn the tyre and the rim and repeat with the second tyre. Lubricate the rim
flange and the bead with suitable lubricants (never use petroleum or silicone base products).
Fit a part of the bead into the rim groove and withdraw the diametrically opposite part by means of two levers.
Proceed until the whole upper bead is free.
After laying the tyre on a solid support, remove the air chamb er. In case of puncture or replacement of the
air chamber only, carefully check the tyre inner condition. Remove any foreign material and make sure the
tyre is well dry inside before fitting the air chamber.
To completely remove the tyre from the rim, locate the remaining bead lower part into the groove. Fit the lever
to the diametrically opposite part
A second lever can help to remove the bead, part by part.

Assembly

Before fitting a new tyre to a second hand rim, make sure the bead laying area is clean and with no corrosion.
It is suggested to clean this area with a metal brush to remove soil and rust. Lay the rim to the ground with
the valve hole upwards. Lightly preinflate the air chamber and fit it into the tyre with the valve upwards, before
starting assembly operations on the rim.
Lubricate the tyre bead as well as the rim flange with an appropriate lubricant solution (never use petroleum
or silicone base products). Raise the first bead by hand as high as possible on the flange. Fully raise the first
bead on the flange, by means of the suitable tool.
Start the assembly of the second bead using the lever. Start from the side opposite to the valve. It is important
that the bead is fitted inside the rim groove.
Make sure the air chamber is not pinched by the tool.
Lubricate the remaing part.
Push the remaining bead over the flange by small pieces.
The operation can be easier standing on the tyre and keeping the bead inside the groove with your own weight.
For the assembly it can be necessary that a second person keeps the fitted bead part inside the groove with
the help of a lever or his own weight.
Carefully center the the tyre on the rim to raise the bead over its flange and to avoid dangerous bead breakage.
Do not inflate the tyre vertically but lay it horizontally. Do not exceed 2.5 atmospheres.
If the beads are not raised at this pressure, do not insist.
Deflate the tyre, check for lubrication and centering and repeat the operation. 21599 60406991
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UNDERCARRIAGE EX135W

1.6 BLADE ASSEMBLY

The machine can be equipped with a blade for small levelling works.
The blade assembly essentially consists of a blade, two upper levers connecting the installation plate with the
blade, and a lower lever that, beside connecting blade and installation plate, receives the motion by means
of retraction or extension of the cylinders.

14 8
15 9

6
5

10
13 2
2
7
16

12
2
3

11

F3793
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1 - Blade 9 - Ring
2 - Upper lever 10 - Greasing nipple
3 - Lower lever 11 - Reflector stand
4 - Plate 12 - Left Cylinder
5 - Right Cylinder 13 - Screw
6 - Pin, 40 mm diameter 14 - Locking nut
7 - Seal scrapper 15 - Washer
8 - Pin 16 - Cover
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UNDERCARRIAGE EX135W

1.7 LATERAL STABILIZERS

The machine can be equipped with one or two couple of stabilizers (outriggers) that assure, together with
locking axle system, the machine stability during the working operation.
The stabilizers unit is composed of a main body consisting of welded steel sheet on which ends are connected
two triangular arms.
On the free ends of the arms are connected the two feet.
The rod of control cylinders are connected to the arm middle points, the bottom of cylinder are connected to
the main body.

2
3

1
4

F3794
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1 - Main body
2 - Arms
3 - Feet
4 - Hydraulic cylinder
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UNDERCARRIAGE EX135W

1.8 HYDRAULIC HOSES AND UNDERCARRIAGE COMPONENTS

1.8.1 HYDRAULIC TRAVEL MOTOR HOSES

The travel hoses control the forward and reverse movement, the low and the high travel speed.
All hoses connect the rotary joint to the hydraulic travel motor.

2
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F7478

1 - Rotary joint
2 - Hydraulic travel motor
3 - Motor brake control solenoid valve.
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UNDERCARRIAGE EX135W

Braking control solenoid valve

- Technical data
Power supply: 24 V d.c.
Bath oil solenoid
Emergency control
Maximum work pressure:
- A and B ports: 315 bar
- T port: 160 bar
Maximum oil flow: 60 l/min.

2 5 1 3 5

4
6 4

F3796

The valve consists of a spool actuated by a solenoid.

The solenoid valve essentially is composed of a body (1), a solenoid (2), a control spool (3) and two centring
springs (4).
With solenoid not excited, the control spool (3) is hold in rest position by means of springs (4).
The movement of control spool (3), is obtained supplying electrical power to the solenoid (2).
The suction force of solenoid (2) pulls the control spool through the rod (5) shifting from rest to work position.
The emergency hand control (6) allows to shift the control spool (3) without exciting the solenoid. 21599 60406991
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UNDERCARRIAGE EX135W

1.8.2 TRANSMISSION UNIT HOSES

The hoses connect the rotary joint to the transmission unit through the transmission control solenoid valves.

6
10 5

1 7
2

4
8
9
3

1 - Rotary joint
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2 - Transmission control solenoid valves assembly F7461

3 - Transmission unit
4 - Travel hydraulic motor
5 - Hydraulic oil supply hose
6 - Accumulator
7 - Drain hose
8 - Shift gear cylinder control hose
9 - Clutch cylinder control hose
10 - Non return valve (only Italy version)é
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UNDERCARRIAGE EX135W

Transmission control solenoid valves assembly

Technical data
Power supply: 24 V d.c.

1 2
4 5 9 7

3 8 6

F3798

1- Drain (marked with “0”)

2- Supply to gear shift cylinder (marked with “3”)
3- Supply to the control clutch (marked with “1”)
4- Hydraulic supply (marked with “2”)
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5- Supply to parking brake (marked with “4”)

6- Spring plug
7- Parking brake solenoid valve (marked with “A”)
8- Clutch control solenoid valve (marked with “C”)
9- Shift gear cylinder control solenoid valve (marked with “B”)
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UNDERCARRIAGE EX135W

1.8.3 WORK AND PARKING BRAKE HOSES

The brake hoses connect the rotary joint to the front and rear axles braking devices.
The parking brake operates on the rear axle. It is controlled by the transmission control solenoid valves
assembly.

2
3

6
4
5
1
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F7508

1 - Front axle work brake hose

2 - Transmission parking brake hose
3 - Transmission control solenoid valve group
4 - Rotary joint
5 - Rear axle work brake hose
6 - Pressure gauge
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UNDERCARRIAGE EX135W

1.8.4 STEERING HOSES

The steering hoses connect the rotary joint to the steering cylinder; this, operating on the swivel joint box,
performs the steering movement on front wheels.

1
1
2

F7509
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1 - Steering hose
2 - Steering cylinder
3 - Rotary joint.
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UNDERCARRIAGE EX135W

1.8.5 FRONT AXLE LOCKING AXLE CYLINDERS HOSES

These hoses connect the rotary joint to the two cylinders operating on front axle.
The axle locking valve, controlled by a solenoid valve located in the solenoid valves assembly, allows the
following operations:
- axle locking, when the two cylinders are not in communication each with other caused by the insertion of
the axle locking valve. The hydraulic oil remains then trapped in the related cylinders avoiding the axle rock;
- controlled damping when the two cylinder are in communication each other (axle locking valve not inserted).
The hydraulic oil can flow from one cylinder to the other allowing the damped rocking of the front axle.
2
1
6
1
2

7
3
5

8
4

8
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1 - Axle locking cylinders

2 - Axle locking valve
3 - Rotary joint
4 - Axle locking valve control and supply hose
5 - Drain hose F6971

6 - L. H. cylinder control pipe

7 - R. H. cylinder control pipe
8 - Pressure reducing valve (from 40 bar to 5 bar)
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UNDERCARRIAGE EX135W

Axle locking valve

- Technical data
Operating pressure: 350 bar
Capacity: 120 L/min
Weight: kg 1.400

F6974
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UNDERCARRIAGE EX135W

Pressure reducing valve

- Technical data
Inlet operating pressure: 40 Bar
Capacity: 30 L/min
Weight: kg 1.650
Output pressure: 5 Bar

F6975
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UNDERCARRIAGE EX135W

1 - Hydraulic cylinder.
2 - Axle locking valve.
3 - Reduction valve.

3
2
1

2
1

F7141
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UNDERCARRIAGE EX135W

Axle locking hydraulic cylinder

- Technical data:
N. 2 hydraulic cylinder at simple effect and in communication
Cylinder stroke: 150 mm (5.905 in)
Rod diameter: 90 mm (3.543 in)
Max. work pressure: 400 bar
Upper bore thread for control hose connecting: 1/8 GAS
Lower bore thread for circuit air drain: 1/8 GAS
Weight: 36 Kg (each)

285
3 4
5

90

180
132

2
F9360

1 - Housing
2 - Cylinder rod
3 - Guiding ring
4 - Seal
5 - Scraper ring
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UNDERCARRIAGE EX135W

1.8.6 LATERAL STABILIZER HOSES

The hoses for lateral stabilizers controlling, allow to separately operate the two cylinders in order to stabilize
the machine even in severe work conditions.
In the control system two solenoid selector valves work (Blade and stabilizer version).
One of this is installed near the rotary joint and operates to allow the oil flow to blade cylinders or to the stabilizer
cylinders. (Optional valve depending on version).
The other solenoid selector valve, located on the lateral stabilizer body, allows to choose the left or right
cylinder movement.
In the case of four lateral stabilizers version, only one solenoid selector valve is used.
Operating on the pilot pressure, can be controlled at the same time the two left stabilizers or the right
stabilizers.
A double check valve is installed on each cylinder that allows to each cylinder to maintain the position without
internal leakage both in work and in travel condition.

4
3
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F3800

1 - Rotary joint
2 - Solenoid selector valve
3 - Double check valve
4 - Stabilizer cylinders
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UNDERCARRIAGE EX135W

Blade/lateral stabilizers selector solenoid valve

This solenoid valve essentially is a spool valve with six way and three positions,
The hydraulic piloting is obtained by means of solenoid valve actuated through a switch located on pilot control
valve.

60
228

C D

85
A B

E F

Hoses connections

A. Supply hose coming from rotary joint (port 7)

B. Supply hose coming from rotary joint (port 6)
C. Supply to right cylinder (to uplift the lateral
stabilizers)
D. Drain from the right cylinder (to uplift the
lateral stabilizers)
E. Supply to left cylinder (to uplift the lateral
stabilizers)
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F. Drain from left cylinder (to uplift the lateral

stabilizers).
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UNDERCARRIAGE EX135W

Double check valve

- Technical data:
Port connections: 1/2“ GAS
Max. working pressure: 350 bar
Oil flow according to the diagram

38 110 38 35

C2 C1

50
V2 V1
1/2" GAS 1/2" GAS

Flow Q (l/min)
0 10 20 30 40 50
12
Pressure ∆p - (bar)

10
c
v-

8
v
6 c-

4
2
0

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UC5-1-35

UNDERCARRIAGE EX135W

Stabilizer Cylinders

- Technical data
- Rod diameter: 80 mm (3.14 in)
- Inner body diameter: 125 mm (4.92 in)
- Outer body diameter:150 mm (5.90 in)
- Maximum stroke: 381 mm (14.99 in)
- Supply and return port connections: 1/2 GAS
Ø 80

381
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UC5-1-36

UNDERCARRIAGE EX135W

1.8.7 BLADE CONTROL HOSES

These hoses connect the rotary joint to the two blade lifting cylinders. The cylinders are in communication with
each other by means of pipes in order to perform an uniform motion.
Depending on machine version, in the blade control circuit could be a solenoid valve to select the lateral
stabilizer. This valve is included only if it is necessary to select hydraulic oil for side outrigers control.
In the circuit are installed two double check valve, one each hydraulic cylinder.

2
3

1
4 2
3

21599 60406991

F6972

1 - Rotary joint
2 - Hydraulic cylinder
3 - Double check valve
4 - Selection valve
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UC5-1-37

UNDERCARRIAGE EX135W

Blade cylinders

- Technical data
- Rod diameter: 56 mm (2.2 in)
- Inner body diameter: 90 mm (3.54 in)
- Outer body diameter: 112 mm (4.40 in)
- Maximum stroke: 200 mm (7.87 in)
- Supply and return connection hoses: 3/8 GAS

Ø 112
Ø 90
Ø 56

200
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UC5-1-38

UNDERCARRIAGE EX135W

NOTES:

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OPERATION PRINCIPLE HYM5-2-1
(O/P)
TRAVEL HYDRAULIC MOTOR EX135W

2. TRAVEL HYDRAULIC MOTOR

2.1 TRAVEL HYDRAULIC MOTOR

2.1.1 DESCRIPTION

The travel hydraulic motor has the purpose of transmitting the motion, through the transmission, to the front
and rear axles.
The travel hydraulic motor is of a bent axis (bent body), variable displacement type with a group of tapered
axial pistons.
The displacement regulator is mounted in the travel motor head.
The displacement can be changed in a continuous mode within the maximum displacement (Vgmax.) and
minimum displacement (Vgmin.) ratio:
Vgmax : Vgmin = 4.85.
When at travel break away or during up-hill travels, the displacement of the motor increases, thus the travel
force increases.
To obtain maximum travel speed, the displacement of the motor must result at minimum value.

The travel hydraulic motor is composed, essentially, of the following parts:

1 - Rotor group
2 - Regulator group
3 - Brake valve
4 - Positioning piston
5 - Housing

1
5 4 2
B S A

T P

T B A

X G

MB
3 MA
21599 60406991

F7015
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HYM5-2-2
(O/P)
TRAVEL HYDRAULIC MOTOR EX135W

2.1.2 ROTOR GROUP

The rotor group is composed of: valve plate (1), seven pistons (2), drive shaft (3), cylinder block (4), spring
(5), center shaft (6), bearings (7), seal (8).
The pressure of the hydraulic oil is applied through valve plate (1) to the piston and the latter, under the action
of the oil, makes an extending stroke and being connected to the drive shaft, their movement is changed into
a rotary motion of the drive shaft itself.
The cylinder block rotates with the pistons, that, in a sequence of extending strokes, generate a torque output
on the drive shaft.
The oil, after moving the pistons, is discharged in the return line by the pistons themselves during the retracting
phase.
The cylinder block can change its angle with respect to the axis of the shaft 5° through 25°. By changing the
angle, the stroke of the piston is changed, thus the torque generated.
The output torque of the drive shaft is a function of the hydraulic pressure and the angle of the cylinder block,
whereas the rotation speed is a function of the oil displacement and the angle of the cylinder block; in practice,
by reducing the angle of the cylinder block, the speed increases and the traction force decreases, by
increasing the angle, the speed is reduced and the traction force increases.

2
1

3
8

6
7 2 F7017
7 5
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1 - Valve plate
2 - Piston
3 - Drive shaft
4 - Cylinder block
5 - Spring
6 - Center shaft
7 - Bearings
8 - Seal
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OPERATION PRINCIPLE HYM5-2-3
(O/P)
TRAVEL HYDRAULIC MOTOR EX135W

2.1.3 REGULATOR GROUP

The travel hydraulic motor is equipped with an automatic displacement regulator related to the operating
pressure.
Beginning of regulation at Vgmin (min. torque, max. speed)
End of regulation at Vgmax (max. torque, min. speed)
This regulator measures internally the operating pressure in A or B and arranges the angle of the rotor group,
when the operating pressure set on the regulator itself is reached, from Vgmin toward Vgmax, through the
positioning piston.
The regulator is also equipped with an additional piloting acting on connection X that allows the positioning
of the motor in Vgmax, not withstanding the operating pressure.

Low speed control

When turning the low speed switch (turtle) located on the side dashboard, solenoid A3 located in the services
solenoid group is energised.
The piloting pressure, coming from the brake valve group and the priority valve, is regulated by the inner
pressure relief valve of the services solenoids group (35 bar) and reaches solenoid valve A3.
Under energised conditions, this transfers the hydraulic pressure to connection X of the travel motor. The
motor positions itself at Vgmax.
When turning the normal speed switch (rabbit) solenoid valve A3 is de-energised.
Under these conditions, the speed of the travel hydraulic motor is controlled by the regulator of the motor itself.

B A

G
X

MB MA

F7016
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HYM5-2-4
(O/P)
TRAVEL HYDRAULIC MOTOR EX135W

2.1.4 BRAKE VALVE

The braking action is actuated by spool (1) depending upon the pressures at inlet A and outlet B (forward
speed condition) or inlet B and outlet A (reverse speed condition). The braking effect is showing-up when the
differential between the inlet and outlet pressures is such that spool (1) is tending toward neutral condition.
The neutral condition will occur only when the pedal pilot valve is completely released.
To protect the circuit, two pressure relief valves have been mounted. They operate when: the pedal pilot valve
is completely released (braking phase); the hydraulic motor is subject to the action of the front equipment.
These valves have the function of avoiding that the oil pressure trapped inside the circuit by spool (1) of the
brake valve and by check valves (2) exceeds 350 bar.

1
3
5
A B

B S A

6
7
8
9
4
10
13
T P
12
11

B A
X T

MB
MA

F7018
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A - Delivery in forward speed 7 - Spring guide plug

B - Discharge in forward speed 8 - Spring
1 - Brake valve spool 9 - Mushroom
2 - Check valve 10 - Spring
3 - Body 11 - Spring guide
4 - Seal 12 - Mushroom
5 - Spring guide sleeve 13 - Plug
6 - Spring
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DISASSEMBLY AND ASSEMBLY HYM5-2-1
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

2.1 DISASSEMBLY AND ASSEMBLY

2.1.1 GENERAL INSTRUCTIONS FOR THE REPAIR

WARNING: The weight of the travel motor is about 47

kg (103 lbs).

• Attention!
Observe the following notices when carryng out
repair work at hydraulic aggregates!

• Close all ports of the hydraulic aggregates.

• Replace all selas.

Use only original Hydromatic spare parts.

• Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abra-
sive paper can damage surface.
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DISASSEMBLY AND ASSEMBLY HYM5-2-2
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

• Fill up hydraulic aggregates with medium before

start-up.

1 Seal kit for drive shaft.

2 External seal kit.

3 Housing. 21599 60406991

4 Complete rotary group

Note: pos. 2 for port plate with synchronizing.

F7019
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DISASSEMBLY AND ASSEMBLY HYM5-2-3
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

5 Port plate with control piston

For port plate with synchronizing piston.

F7020

6 Cover with throttle pin*

* throttle pin as to order requiriment.

7 Cover with flushing and boots pressure valve and

throttle pin*
* throttle pin as order requiriment.
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DISASSEMBLY AND ASSEMBLY HYM5-2-4
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

• Control element.

F7022

8 Replace seal nut:

first measure and record setting height.

9 When tightening, counterhold setting screw, then

check setting height.

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DISASSEMBLY AND ASSEMBLY HYM5-2-5
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

F7023

10 Protecting the drive shaft.

Remove retaining and shim.

11 Screw in sheet metal screw into the holes fitted

with rubber.
Pull out seal with pliers.

12 Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth*.
Install mark for press-in depth of safety ring.
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DISASSEMBLY AND ASSEMBLY HYM5-2-6
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

13 Attention!
Spring load.

14 Inspect
Drilling in housing, O-ring, groove.

15 Do not remove adjustment screw.

Inspect: O-ring, O-ring groove, housing.

16 Assembly aid:
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insert pin with grease.

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DISASSEMBLY AND ASSEMBLY HYM5-2-7
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

F7024

17 Example: A6VM ....HD control

Disassembly position:
Remove cover pos. 1

Pos. 1

18 (1) O-ring
(2) Imput flow of oil control.
(3) Throttle pin.

Installation position differs according to the

control components.

19 (1) input flow of oil control

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(2) high/low pressure

(3) high/low pressure
(4) leckage oil
(5) cotrol piston
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DISASSEMBLY AND ASSEMBLY HYM5-2-8
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

F7024

20 Example: A6VM ....control - differential piston.

Disassambly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

21 (1) Check of O-ring.

22 (1) hight pressure: small control piston side

(2) control pressure
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(3) hight pressure: check valve

(4) hight pressure: check valve.
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DISASSEMBLY AND ASSEMBLY HYM5-2-9
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

• Synchronizing piston:
note dimension x.

• For disassembly of the port plate, swivel always

rotari group to zero position.

• Remove Qmin -screw and plug.

• Swivel rotary group to zero position with screw

Qmin.
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DISASSEMBLY AND ASSEMBLY HYM5-2-10
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

23 Port plate.
Mark position.
Loosen screws.
Removal.

24 Replace O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder
boring.

25 Stick control lens in sliding surface with

grease.
Assembly in reversal order.
Mount port plate.

Rotary group vertical.

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DISASSEMBLY AND ASSEMBLY HYM5-2-11
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

26 Synchronizing piston.

F7025

27 Loosen fixing screw.

Use only socket wrench.

28 Remove piston with piston ring.

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DISASSEMBLY AND ASSEMBLY HYM5-2-12
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

29 Synchronizing piston
Remove screw.
Remove piston.

Not installation position.

30 Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax-stop screw.

Size: 28 : M4 x 58 mm
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55 : M5 x 71 mm
80 : M6 x 82 mm
107 : M6 x 92 mm
140 : M8 x 105 mm
160 : M8 x 105 mm
200 : M6 x 109 mm
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DISASSEMBLY AND ASSEMBLY HYM5-2-13
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

31 Press out rotary group.

If the bearings are used again, do not hit on
the drive shaft.

32 Press-out the rotary group with extraction device.

33 Complete rotary group calettato

Setting of hydraulic part necessary.

F7026
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DISASSEMBLY AND ASSEMBLY HYM5-2-14
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

34 Rotary group
1. mechanical part: adjust drive shaft with bearing
2. hydraulic part: adjustment necessary*

35 Rotary group: all parts

* setting
setting value, torque see service information.

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DISASSEMBLY AND ASSEMBLY HYM5-2-15
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

36 Remove fixing screw (cylinder).

Remove cylinder.

37 Disassemble retaining plate.

Screws are glued.
Use Torx-tools.

38 Free of corrosion, erosion or fretting, no damage

to splines or keyways.
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DISASSEMBLY AND ASSEMBLY HYM5-2-16
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

39 Pistons: no scoring and no pittings.

40 Center pin: no scoring and no pittings.

41 Retaining plate: no scoring and no evidence of

wear.

42 Cylinder block / control lens:

1. bores free of scoring, no evidence of wear
2. faces smooth and even, free of cracks and
scoring. 1

1
2
2
F6852

43 Control housing: sliding surface and side guides

free of scoring and no wear.
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DISASSEMBLY AND ASSEMBLY HYM5-2-17
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

44 Visual check: bearing areas free of scoring and

no evidence of wear.

• Rotary group: machanical part

Adjustment dimension* and bearing torque: see
service information.

Press on bearing.
Do not exeed bearing torque during press-on.

Preload bearing with assembly sleeve and steady

control of the torque.
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DISASSEMBLY AND ASSEMBLY HYM5-2-18
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

• Rotary group: mechanical part

Assemble safety ring.

Detrmine dimension* for adjustment disc with final
dimensions (crossover).

• Insall adjustment disc.

Assemble safety ring.
Drive shaft ready for assembly.
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DISASSEMBLY AND ASSEMBLY HYM5-2-19
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

F7068

45 Insert retaining plate with piston and center pin.

Pin screw with Precote-coating.

46 Make sure all pars are fitted in correctly.

47 Swivel cylinder block to max. and fix the cylinder.

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DISASSEMBLY AND ASSEMBLY HYM5-2-20
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

• Rotary group completely assembled ready for

assembly.

• Place assmbly sleeve.

• Warm up housing to 80°C.

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DISASSEMBLY AND ASSEMBLY HYM5-2-21
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

• Insert rotary group into housing to seat position.

• Fix zero position of cylinder with Qmax "screw".

1. disassemble cylinder fixing screw
2. insert O-ring.
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DISASSEMBLY AND ASSEMBLY HYM5-2-22
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

48 Determine cylinder swivel range to max. angle

screw.

49 *Disc

50 Place centering disc.

51 Mount measuring device.

52 Check dimension x.
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DISASSEMBLY AND ASSEMBLY HYM5-2-23
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

53 1. Assemble port plate with synchronizing piston.

Take care of assembly design!

Tighten fixing screws wit torque.

2. Swivel rotary group to starting position.

3. Set Qmin screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

54 Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.

Take care of press-in depth.

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DISASSEMBLY AND ASSEMBLY HYM5-2-24
(D/A)
TRAVEL HYDRAULIC MOTOR EX135W

Tightening torques for shaft bolts THREAD STRENGTH CLASSES

(metric ISO standard)
8.8 10.9 12.9
SIZE TIGHTENING TORQUE (lb.ft.)
The values for tightening torques shown in the M3 1,1 1,6 1,9
table are valid only for shaft bolts with metric M4 2,9 4,1 4,9
ISO-standard threads and head support surface M5 6 8,5 10
dimensions in accordance with DIN 912, DIN M6 10 14 17
931 e DIN 933. M8 25 96 41
These values are also valid only for light or M10 49 69 83
unoiled, untreated surface as well as for use M12 86 120 145
only with torque-indicating wrenches and force M14 135 190 230
limiting tools. M16 210 295 355
M18 290 405 485
M20 410 580 690
M22 550 780 930
M24 710 1000 1200
M27 1050 1500 1800
M30 1450 2000 2400

Tightening torques for locking screws VSTI THREAD SIZE DESIGNATION TIGHTENING
(metric ISO fine thread) TORQUES (lb.ft)
M8x1 VSTI 8 x 1 -ED/SA 5
M10 x 1 VSTI 10 x 1 -ED 10
M12 x 1.5 VSTI 12 x 1.5 -ED 20
M14 x 1.5 VSTI 14 x 1.5 -ED 30
M16 x 1.5 VSTI 16 x 1.5 -ED/SA 30
M18 x 1.5 VSTI 18 x 1.5 -ED/SA 40
M20 x 1.5 VSTI 20 x 1.5 -ED/SA 50
M22 x 1.5 VSTI 22 x 1.5 -ED 60
M26 x 1.5 VSTI 16 x 1.5 -ED/SA 70
M27 x 2 VSTI 27 x 2 -ED 90
M30 x 1.5 VSTI 30 x 1.5 -ED/SA 100
M33 x 2 VSTI 33 x 2 -ED/SA 120
M42 x 2 VSTI 42 x 2 -ED/SA 200
M48 x 2 VSTI 48 x 2 -ED 300

Tightening torques for seal-lock nuts THREAD STRENGTH CLASSES

(metric ISO-standard thread)
8.8 10.9 12.9
The values for tightening torques shown in the SIZE TIGHTENING TORQUE (lb.ft.)
table are valid only for seal-lock nuts of the M6 10
strenght class 8.8 and with metric ISO-standard M8 22
thread. M10 40
M12 69
M14 110
M16 170

Tightening torques for cross-slotted lens head THREAD STRENGTH CLASSES

screws DIN 7985
21599 60406991

(metric ISO-standard thread) 8.8 10.9 12.9

SIZE TIGHTENING TORQUE (lb.ft.)
The values for tightening torques shown in the M3 1.1
table are valid only for cross-slotted lens head M4 2.9
screws DIN 7985 of the strenght class 8.8 and M5 6
with metric ISO-standard thread. M6 10
M8 25
M10 49
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OPERATION PRINCIPLE TM5-3-1
((O/P)
TRANSMISSION EX135W

3. TRANSMISSION

3.1 TRANSMISSION

3.1.1 OPERATION

The mechanic energy produced by hydraulic travel motor is applied to the front and rear axles by means of
the transmission.
The transmission is an automatic and electronic controlled type with two synchronized gears, and it is directly
installed on the rear axle.
The device has two ratios and the change from one ratio to the other can only be made if the clutch is
disengaged.
In order to disengage the clutch 1, hydraulic pressure is needed to be applied to the control cylinder 2; if the
hydraulic pressure drops, the clutch is automatically engaged by means of the action of the spring 3 against
the clutch disks assembly 4.
The gear ratio is selected by the movement of shift cylinder 5 that is controlled by the hydraulic pressure P
to engage the first speed gear, and by mechanical reaction carried out by the precharged spring 6 to engage
the second speed gear. That means with no hydraulic pressure the shift cylinder is always positioned to the
second speed gear.

5
6
P
2

1
3
4
21599 60406991

F6878
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OPERATION PRINCIPLE TM5-3-2
((O/P)
TRANSMISSION EX135W

A mechanical protection of “speed gear lock” 1 makes sure the shift cylinder can not be moved as long as the
clutch is engaged.

1 F3803

All operation selections of the transmission are controlled by the APC 50 microprocessor which continuously
computes all input information, as electric signals, generated from sensors and switches. 21599 60406991
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OPERATION PRINCIPLE TM5-3-3
((O/P)
TRANSMISSION EX135W

3.1.2 SPEED GEAR RATIOS

The two speed gear ratio in the gear box are built with mating helical gears. The gears are installed on roll
bearings with the exclusion of A gear, splined on the synchronizer shaft B, and C gear, splined on output shaft
D.

SECOND SPEED GEAR

Transmission ratio 1 : 1.96

A
With no
pressure B

Motion
inlet

Clutch control
pressure

C
21599 60406991

F6880

A = Control gear (Z = 25)

B = Synchronizer shaft
C = Output gear (Z = 49)
D = Output shaft
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OPERATION PRINCIPLE TM5-3-4
((O/P)
TRANSMISSION EX135W

FIRST SPEED GEAR

Transmission ratio 1 : 7.445

Gear control
pressure

Motion inlet

Clutch control
pressure

F6879
21599 60406991

P = Pilot hydraulic pressure

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OPERATION PRINCIPLE TM5-3-5
((O/P)
TRANSMISSION EX135W

3.1.3 HAND OPERATED SPEED GEAR CONTROL (MACHINE STANDING STILL)

Positioning the control lever 3 to forward direction I, it will be selected the first speed gear; at the same time
the warning light 4 will be on.

5
4 I

15 20
10 25 P
5 Km/h
30

3
II

F6882

An electrical signal will be sent to the APC 50 microprocessor that will activate in order to engage the first speed
gear; on the monitor display will appear the number “1”.
The microprocessor APC 50 controls the gear shift as follows:

- By means of the solenoid valve “C” excitation, it will supply hydraulic pressure to the clutch control cylinder
7 and to unlock gear device with consequential clutch disengagement. The unlock gear control will happen
with a delay of 5 seconds in order to guarantee that the control gearshift will move only with clutch in open
position.

- By means of excitation of solenoid valve “B”, the pilot hydraulic pressure will supply the shift cylinder 8 for
the engagement of first speed gear.

- Following electric signal input from switch 9 that the gear lock position is reached, the clutch will close again.

Positioning control lever 1 toward rear II, it will be selected the second speed gear and the related warning
21599 60406991

light 5 will be on.

With this control lever movement, it will be sent an electric signal to APC 50 microprocessor which will control
the sequence of operation in order to disengage the first speed gear and to engage the second speed gear.
The sequence of operation is similar to the sequence of first speed gear engagement already shown, with only
the change that the shift cylinder, when is controlled by hydraulic pressure (and therefore solenoid valve “B”
energized) engage the first speed gear; meanwhile to engage the second speed gear the hydraulic pressure
will not to be applied to the shift cylinder and therefore the solenoid valve “B” must be de-energized.
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OPERATION PRINCIPLE TM5-3-6
((O/P)
TRANSMISSION EX135W

2
21 22
19
APC 50
1
14

15 6 5 4

7 C

12 4

B
8 C B A
2 5

F
1 3 4 3
9
10 D

11 F6883

1 - Speed selector
2 - APC 50 microprocessor
3 - Transmission solenoid control valves
4 - Accumulator
5 - Pilot pump
6 - Transmission
7 - Clutch cylinder
8 - Shift cylinder
9 - Lock speed gear switch
10 - Speed sensor
11 - Rear Axle
12 - Parking brake cylinders
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OPERATION PRINCIPLE TM5-3-7
((O/P)
TRANSMISSION EX135W

3.1.4 AUTOMATIC CONTROL

With speed change control lever 3 positioned at middle A, the automatic control operation of transmission will
be set.
In this condition, the control of shift speed gear depends on revolution speed of driving shaft.

5
4 I

15 20
10 25 P
5 Km/h
30

3
II

F6882

The revolution speed is detected by speed sensor installed on housing transmission which transmits the
revolution per minute of output gear (Z51) to the APC50 microprocessor.
If the machine speed is increasing, when the APC50 microprocessor detects a speed level greater than 520
revolutions per minute, it will send signals to the solenoid control valves to start the sequence in order to shift
the speed gear from the first to the second speed gear.
When the second gear is reached, the lock speed gear switch, controlled by a cam built-in on shift control rod,
sends the signal to confirm the gear engagement to APC50 microprocessor. This in turn, will de-energize the
solenoid valve “C” , and therefore the clutch will close again.
After completion of shift sequence, the monitor display will show the new speed gear engaged.
With the second speed engaged, if the machine speed is decreasing, as soon as the microprocessor detects
a speed level lower than 20 revolutions per minute, APC50 will send a signal to the solenoid control valves
assembly to start the sequence in order to shift the speed gear from the second to the first.
21599 60406991

Both upshift and downshift speed gear sequence, if the lock speed gear switch will not detect that the shift
cylinder has reached the stable position in the established time, the sequence will be repeated trying again
until the correct engagement has been reached. After a maximum of 5 unsuccessful attempts, the
microprocessor abandons the control of speed gear, leaving it in the previous position.
On monitor display, are shown the information of status of machine that can be selected by pushing the display
sequence button.
Other than the display of gear position and the error code, it can be shown the number of revolutions per minute
of output shaft, the machine speed, and perform a check of input and output signals of transmission.
For further information, make reference to Electrical System Section.
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OPERATION PRINCIPLE TM5-3-8
((O/P)
TRANSMISSION EX135W

How does the APC 50 program try to reach a stable gear

No movement
Wait for the shiftcylinder to after 1.5 seconds

▲
move.

Movement detected ▲

Wait for the shiftcylinder to stop Still moving

▲
moving. after 1.5 seconds

Movement
stopped ▲

Yes
Desired gear
reached?

▲ No

If all the attempts have not been

▲

made, try the other gear.

Every attempt made

▲

Yes
Was the other
gear possible?

▲ No

Open the clutch block the sys-

tem.

Select the other gear.

▲

21599 60406991

Close the clutch.

▲
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OPERATION PRINCIPLE TM5-3-9
((O/P)
TRANSMISSION EX135W

3.1.5 KICK DOWN FUNCTION

The purpose of kick down function is to provide an acceleration or an addition pushing action in special travel
condition.
A pressure switch calibrated at 20 bar is installed on pilot pressure line, after travel pedal control valve on
forward travel side.
When the selector speed is in automatic position the APC 50 microprocessor controls the shift gear sequence
in relation with the number of revolutions per minute of output shaft and speed rate (acceleration or
deceleration).
With pedal pilot valve moved not more than about half stroke, the pilot pressure is not greater than 20 bar,
therefore the kick down pressure switch is in open position.
In this conditions, if the speed detected from sensor is about 520 revolutions per minute in increasing, APC
50 microprocessor provides signals for speed gear sequence to shift from the first to the second speed gear.
If the revolution speed is about 20 r.p.m. in decreasing, APC 50 microprocessor provides signals for speed
gear sequence to shift from the second to the first speed gear.
When instead the pedal pilot valve is moved toward stroke end so that the pilot pressure is greater than 20
bar, the kick down pressure switch sends an electric signal to the APC 50.
The APC 50 microprocessor, understanding the pilot valve movement toward stroke-end as driver intention
to obtain an increasing acceleration or additional push, changes the threshold of automatic control operation.
The control values of automatic control operation with kick-down function activated will increase as follows:

- Speed to 550 revolutions per minute and in increasing, the microprocessor controls the shift sequence from
the first to the second speed gear.

- Speed to 220 revolutions per minute and in decreasing; the microprocessor controls the shift sequence from
the second to the first gear.

This threshold change of shift operation allows to the machine to improve its travel behaviour during high traffic
condition or climbing routes.
21599 60406991
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OPERATION PRINCIPLE TM5-3-10
((O/P)
TRANSMISSION EX135W

NOTES:

21599 60406991
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DISASSEMBLY AND ASSEMBLY TM5-3-1
((D/A)
TRANSMISSION EX135W

3.1 TRANSMISSION ASSEMBLY AND DISASSEMBLY

Descriptional Transmission unit assembly:

1. - Transmission assembly 2. - Clutch assembly 3. -

Gear shifting cylinder
1.1 - Synchronizer control rod 2.1 - Clutch 3.1 -
Spring
1.2 - Synchronizer 2.2 - Clutch cylinder 3.2 -
Central screw
1.3 - Gear (Z 26) 2.3 - Clutch disks 3.3 -
Threaded bush
1.4 - Gear (Z 52) 2.4 - Bush gear 3.4 -
Control cylinder
1.5 - Splined gear (Z 26) 2.5 - Input shaft 3.5 -
Pin
1.6 - Double gear (Z 49, Z 24) 3.6 -
Control cylinder lever
1.7 - Final gear (Z 51) 3.7 -
Lock speed gear security
1.8 - Flange switch
1.9 - Output shaft 3.8 - Lock speed gear device
1.10 - Speed sensor
1.11 - Synchronizer shaft 4. - Parking brake cylinder
1.12 - Lubrication pipe 4.1 - Cylinder
1.13 - Cover plate 4.2 - Clutch discs
1.14 - Plug 4.3 - Spring

3.5 3.6 3. 3.4 3.1 3.3 3.2

2. 1.3 1.1 1.4 1. 1.2 1.5

1.12

4.
4.1
4.2
4.3

1.11
1.9

2.5 2.2 2.1 2.3 2.4

3.8 3.7 1.8

21599 60406991

1.6

1.7
1.1
1.10

1.14 1.13
F6881
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DISASSEMBLY AND ASSEMBLY TM5-3-2
((D/A)
TRANSMISSION EX135W

3.1.1 INTRODUCTION

- Before starting disassembling operations, important thing is to clean the transmission and the work
bench.

- It is advisable to mark all the shims for the assembling operations.

- Place the transmission on a work bench and be sure that the oil has already been drained from unit.

- Verify the identification plate recording the transmission type and unit.

- Remove the delicate parts (e.g. speed sensor, lock gear switch, etc.).

WARNING: the weight of the transmission is about 115 kg (254 lbs).

Disassembly of assembly
Renew at each reassemble
groups

Reassemble to assembly group

Unlock-lock

Remove obstruction parts Lock - adhere (liquid sealant)

Reinstall-remount parts which had Guard against material damage, damage

obstructed disassembly to parts

Mark before disassembly, observe marks

Attention, important notice when reassemble

Check - adjust e.g. torque, dimensions, Filling - topping up - refilling e.g. oil,
pressure, etc. cooling water. Etc.

T = Special tool
Drain off oil, lubricant
P = Page

Note direction of installation Tighten

21599 60406991

Visual inspection Apply pressure into hydraulic circuit

Possibly still serviceable, renew if Clean

necessary
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DISASSEMBLY AND ASSEMBLY TM5-3-3
((D/A)
TRANSMISSION EX135W

3.1.2 TRANSMISSION DISASSEMBLY

1 By actuating the unlock shifting lever,

be sure the first speed gear is not
engaged. Beware of oil spilling.

F2579

2 Remove screws of gear shifting

cylinder.

F2580

3 Withdraw the gear shifting cylinder

forcing with a normal lever.

F2581

4 Remove screws of input shaft and

clutch unit.
21599 60406991

F2582
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DISASSEMBLY AND ASSEMBLY TM5-3-4
((D/A)
TRANSMISSION EX135W

5 Withdraw the input shaft and clutch

unit actuating the unlock shifting
lever.

F2583

6 Remove nut fixing the flange and O

ring.

F2584

7 Withdraw the flange.

F2585

8 Remove screws.
21599 60406991

F2586
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DISASSEMBLY AND ASSEMBLY TM5-3-5
((D/A)
TRANSMISSION EX135W

9 Remove guide bush of shifting control

rod, paying attention not to damage
O ring.

F2587

10 Force in the proper slots.

F2588

11 Detach the cover with aid of levers.

F2589

12 Withdraw the cover be carefully to

synchronizer control rod.
Remove the speed sensor.
21599 60406991

F2632
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DISASSEMBLY AND ASSEMBLY TM5-3-6
((D/A)
TRANSMISSION EX135W

13 Remove bearing 6308, by means of

lever, paying attention of spacer and
shims.

F2591

14 Using a proper tool, withdraw the

double gear and the cover plate.

F2592

15 Check for correct position.

F2593

16 Remove the lubrication pipe.

21599 60406991

F2594
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DISASSEMBLY AND ASSEMBLY TM5-3-7
((D/A)
TRANSMISSION EX135W

DISASSEMBLY NEGATIV BRAKE

17 Remove negative brake cover

screws.

F2595

18 Remove brake Bellevue washers.

F2657

19 Remove brake piston and discs.

F2658

20 Remove the brake cover nuts.

21599 60406991

F2597
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DISASSEMBLY AND ASSEMBLY TM5-3-8
((D/A)
TRANSMISSION EX135W

21 Remove brake cover.

F2610

22 Remove spacer bearing block.

F2612

24 Insert the shaft completely towards

outside.

F2596

• Remove the O-ring and the

antiextrusion rings pulling rings them
gently.
21599 60406991

F7062
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DISASSEMBLY AND ASSEMBLY TM5-3-9
((D/A)
TRANSMISSION EX135W

• Check the measurement of the brake

disks before mounting.
Check the condition of the discs.
New disk measurement = 2.1.
Max. vorn disk measurement = 1.75.

• Reinsert the brake disks alternately.

The first with external tangs,
alternating them; the last disk also
with external tangs.

F7064

• Before inserting the piston, check

again the exact position of the O-
rings and the antiextrusion rings and
the surfaces of the piston.

F7065

• Note height (A) between surface of

cover and interior of piston, ensuring
that it is resting on the brake disks.
21599 60406991

F7066
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DISASSEMBLY AND ASSEMBLY TM5-3-10
((D/A)
TRANSMISSION EX135W

• Note height (B) between surface of

cover and surface with spacer
inserted onto spring rest. To
determine shim: A-B-18.4 fixed
height = shim to be inserted under
the spacer.

F7070

• Reinsert the springs checking the

exact position.

F7058

• Remount the cover with torque

wrench setting M12 Nm 86÷89.

F7059

• Remountig of lubrication tube.

21599 60406991

F7060
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DISASSEMBLY AND ASSEMBLY TM5-3-11
((D/A)
TRANSMISSION EX135W

• Remove the two plugs (A) and the two

screws (B).
B
• Replace plugs (A) by the two screws
(B).
• Retighten screws (B).
• Tighten screws (B) alternately by 1/2
turn at a time for a total of min. 1.5
turns to ensure release.
Two wrenches are required for this
operation: CH13 for screws (B), CH14 for
screws (A). They are contained in the
machine toolbox. A
Repeat the operations in reverse order for F6580
negative brake connection.

25 Remove bearing snap ring.

F2662

26 Extract the shims (keep the shims

together for possible re-use).

F2676

27 Extract the synchroniser unit shaft.

21599 60406991

F2599
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DISASSEMBLY AND ASSEMBLY TM5-3-12
((D/A)
TRANSMISSION EX135W

28 Remove output shaft.

F2600

29 Remove gear and OR. For

reassembly, reverse the sequence of
operations.

F2601

30 Before starting to reassemble the

transmission, rotate the oil collector
half a turn anti-clockwise, check that
it is clean and reinstall.

F2602
21599 60406991
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DISASSEMBLY AND ASSEMBLY TM5-3-13
((D/A)
TRANSMISSION EX135W

Disassembly and assembly of shaft with synchroniser

Disassembly

1 Remove the snap ring and the

spacer, extract the synchroniser and
the sliding gear with needle bearing.

F2603

2 Slip off the keyed gear and IR,

remove spacer and shims, remove
bearing.

F2604

3 Reassembly: Premount all the

components on the shaft.
With thickness gauge check the end
play for the shim to be fitted under
the keyed gear.

F2603

4 Reassemble output shaft in the

casing.
21599 60406991

F2607
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DISASSEMBLY AND ASSEMBLY TM5-3-14
((D/A)
TRANSMISSION EX135W

5 Insert synchroniser unit shaft in the

casing.

F2599

6 Positioning of the synchroniser shaft

inserting in its housing at end of
stroke.

F2596

21599 60406991
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DISASSEMBLY AND ASSEMBLY TM5-3-15
((D/A)
TRANSMISSION EX135W

3.1.3 REASSEMBLY OF TRANSMISSION

1 Reassemble shim and snap ring

spacer and with plastic hammer
insert shaft to end of stroke.

F2676

2/3 Insert bearing block spacer.

F2612

4 Measure height A between casing

surface and spacer.

F2677
21599 60406991
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DISASSEMBLY AND ASSEMBLY TM5-3-16
((D/A)
TRANSMISSION EX135W

5 Measure height B between cover

surface and border. The play with
shims (see photo 1 page 13) = 0 0.1
mm.

F2678

6 Remount cover checking O-ring.

Then tighten nuts with a torque
wrench setting of Nm 49 ÷ 51 (see
photo 20 page 7).

F2610

7 Remove snap ring to replace needle

bearing if necessary.

F2679

8 Remove snap ring to replace bearing,

if necessary.
21599 60406991

F2613
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DISASSEMBLY AND ASSEMBLY TM5-3-17
((D/A)
TRANSMISSION EX135W

9 Position the reducer horizontally, so

that the flange of the shaft below is
free.
Insert: ring onto synchroniser, casing
and double gear!

F2614

10 Reassemble with tube, striking lightly

on the internal thrust-plate of the
bearing.

F2615

11 Insert spacer and specific ring (h 23

mm) into output shaft.
Measure height A between spacer
and casing (75301367).

F2616

12 Measure height B between cover and

internal housing of bearing to
determine the shims.
21599 60406991

B - A - 0.25 play = Shim.

F2617
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DISASSEMBLY AND ASSEMBLY TM5-3-18
((D/A)
TRANSMISSION EX135W

13 Remove specific ring (h 23 mm) and

insert the spacer determined.

F2618

14 Reinsert the bearing.

F2619

15 Disconnect the snap ring from the

gear and check the condition of the
needle bearings and bearing and
replace if necessary.

F2620

16 Reassemble the complete gear into

the cover and the snap ring.
21599 60406991

F2621
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DISASSEMBLY AND ASSEMBLY TM5-3-19
((D/A)
TRANSMISSION EX135W

20 Assemble the snap ring, bushing and

flange.
Measure height A.

F2622

21 Measure height B on the clutch box.

To determine shims:
B - A = Shim to insert under the snap
ring.

F2623

22 Reinsert the shims and check height

A again leaving play of 0 ÷ 0.1 mm.
(Determined at item 21).

F2624

23 Remove the old sealing ring.

21599 60406991

F2625
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DISASSEMBLY AND ASSEMBLY TM5-3-20
((D/A)
TRANSMISSION EX135W

24 Inserirt the new sealing with the

appropriate tool. (75301368).

F2626

25 Turn the cover resting it in such a way

that the bearing is in the right position
and measure height A between gear
and cover.

F2627

26 Measure height B between box and

ring on the synchronise.
B - A = Play which must be
0.1 ÷ 0.4 mm.

F2628

27 Check the selector pins of the

selector shaft. Assemble the back-up
ring and O-ring only in position 2
underneath. (75301369).
21599 60406991

F2611
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DISASSEMBLY AND ASSEMBLY TM5-3-21
((D/A)
TRANSMISSION EX135W

28 Assemble gear rod in the

synchroniser, close reducer with
cover (use LOCTITE 510 on
surfaces).

F2590

29 Position pins in cover, torque wrench

setting Nm 49 ÷ 51 of M10 screws.
Assemble bushing and OR (1+2 see
photo 9 page 5).

F2629

30 Assemble flange and OR (see photo

6 page 4) using LOCTITE 242 on
thread. Nut: torque wrench setting
Nm 260 ÷ 280.

F2630

31 Locate reducer vertically and reinsert

clutch unit partially assembled,
checking the O-ring position.
21599 60406991

F2631
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DISASSEMBLY AND ASSEMBLY TM5-3-22
((D/A)
TRANSMISSION EX135W

32 Fit the screws and nuts with washers.

Torque wrench setting for M10
screws: Nm 49 ÷ 51.

F2582

21599 60406991
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DISASSEMBLY AND ASSEMBLY TM5-3-23
((D/A)
TRANSMISSION EX135W

3.1.4 DISASSEMBLY OF CLUTCH UNIT

1 Disassembly of clutch unit.

F2583

2 Unscrew the ring nut (partially),

holding the input shaft still.

F2633

3 Remove the snap ring using a press

to unload the tension of the Belleville
washers.

F2634

4 Extract the shims, spacer and clutch

disks.
21599 60406991

F2635
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DISASSEMBLY AND ASSEMBLY TM5-3-24
((D/A)
TRANSMISSION EX135W

5 Extract ring nut, spacer and Belleville

washers.

F2636

6 Remove snap ring.

F2637

7 Remove cover fixing screws.

F2638

8 Remove cover.
Pay attention to height of cover h =
74.1 mm.
21599 60406991

F2639
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DISASSEMBLY AND ASSEMBLY TM5-3-25
((D/A)
TRANSMISSION EX135W

9 Extract gear block piston, taking care

of internal sphere Ø 10 and to remove
the O-rings.

F2640

10 Extract clutch shaft.

F2641

11 Remove clutch unit piston.

F2642

12 Extract the shims, the piston springs,

the O-rings and the antiextrusion
rings.
21599 60406991

F2643
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DISASSEMBLY AND ASSEMBLY TM5-3-26
((D/A)
TRANSMISSION EX135W

13 Remove snap ring and unthread

selector.

F2644

14 Remove sprocket flange.

F2645

15 Remove bearing.

F2646
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DISASSEMBLY AND ASSEMBLY TM5-3-27
((D/A)
TRANSMISSION EX135W

3.1.5 REASSEMBLY OF CLUTCH UNIT

1 Reassembly bearing with the

appropriate tool.

F2647

2 Position the flange on a circular

support to allow introduction of the
cover.

F2648

3 Press the flange into the bearing.

F2649

4 Insert the O-rings and the

antiextrusion rings into the housing
after having pulled them gently with
hands.
21599 60406991

F2650
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DISASSEMBLY AND ASSEMBLY TM5-3-28
((D/A)
TRANSMISSION EX135W

5 Replace the shims.

F2643

6 Position the springs in the piston with

grease and insert the piston.

F2652

7 Insert the selector and position the

snap ring in its housing.

F2644

8 Insert clutch shaft.

21599 60406991

F2641
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DISASSEMBLY AND ASSEMBLY TM5-3-29
((D/A)
TRANSMISSION EX135W

9 Reassemble cover paying attention

to the position of the pins which enter
the piston, tightening the screws
provisionally.

F2653

10 Turn the snap ring upside down and

reinsert in its housing.

F2637

11 Check clutch disks for wear.

New disc measurement = 2.36 mm.
Max. worn disc measurement = 2.03
mm.

F2849

12 Insert snap ring in its housing;

measure height A holding the snap
ring towards the exterior.
21599 60406991

F2655
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DISASSEMBLY AND ASSEMBLY TM5-3-30
((D/A)
TRANSMISSION EX135W

13 Remove snap ring and insert it under

the clutch pack to measure height B
to determine the shs:
A - B - 21 Fixed height = Shims to be
inserted between spacer and last
disk.

F2656

14 Reinsert Belleville washers, the

spacer and bring the ring nut one or
two turns closer.

F2636

15 Reinsert the clutch disks, the 1st with

external sprockets, alternating them.
Last external sprocket disk, shims
and the spacer.

F2635

16 Using the bushing align the clutch

disks.
21599 60406991

F2659
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DISASSEMBLY AND ASSEMBLY TM5-3-31
((D/A)
TRANSMISSION EX135W

17 Using the press, unload the winding

of the Belleville washers and reinsert
the snap ring.

F2660

18 Zero the comparator to height: (mm

74,1 = A 6 V M 80) (mm 80.1 = A 6 V
M 107)

F2661

19 With special spanner. (75301370).

F2663

20 Inserting a punch drift-pin into the

holes in the sprocket flange, screw
up the ring nut (clockwise) until the
comparator inserted in its hole has
reached a stroke of mm 2.1 (74.1 +
2.1 = 76.2).
21599 60406991

F2664
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DISASSEMBLY AND ASSEMBLY TM5-3-32
((D/A)
TRANSMISSION EX135W

21 Once the clutch piston stroke has

been determined, caulk the edge of
the ring nut.

F2665

22 Replace the reducer vertically and

reinsert the partially assembled
clutch unit verifying the position of the
O-ring.

F2631

23 Replace the screws and nuts with the

washers with torque wrench setting
screws M 10 Nm 49 ÷ 51.

F2582

24 Remove fixing screws from cover and

extract it.
21599 60406991

F2638
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DISASSEMBLY AND ASSEMBLY TM5-3-33
((D/A)
TRANSMISSION EX135W

25 Check the sealing ring or replace

before remounting the cover.

F2666

26 Reinsert the O-ring and the antiextru-

sion ring.

F2667

27 Reintroduce the gear release sphere

in its housing using some grease.

F2668

28 Reinsert the gear release pin

checking that O-ring and
antiextrusion rings are inserted in the
correct position.
21599 60406991

Insert the spring.

F2669
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DISASSEMBLY AND ASSEMBLY TM5-3-34
((D/A)
TRANSMISSION EX135W

29 Reinstall cover paying attention to the

position of the pins which enter the
piston, tightening the screws with
torque wrench setting
M8 Nm 25 ÷ 26.

F2670

30 Remount gear release lever using

LOCTITE 270 on the screw.
Torque wrench setting M4 Nm 2.4 ÷
2,5.

F2671

31 Temporary hydraulic safety. Reinsert

spring sphere, washer and screw into
the casing.

F2672

32 Remount screw with washer.

21599 60406991

F2673
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DISASSEMBLY AND ASSEMBLY TM5-3-35
((D/A)
TRANSMISSION EX135W

33 Reinsert the rev. detector or closing

cover with torque wrench setting
screws M8 Nm 25 ÷ 26.

F2674
21599 60406991
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DISASSEMBLY AND ASSEMBLY TM5-3-36
((D/A)
TRANSMISSION EX135W

3.1.6 DISASSEMBLY OF GEAR UNIT CYLINDER

1 Ensure release of 1st spring gear

paying attention to oil leakage.
Remove gear unit cylinder screws.

F2580

2 Extract gear unit cylinder by forcing

with a normal lever.

F2581

3 Remove the cylinder cover screws

and central screw. Measure height on
bushing for remounting.

F2608

4 Remove the threaded bush carefully,

inserting the tool (see photo 5 page
35) completely unscrewing nut and
bush (pay attention to spring tension).
21599 60406991

(75301372).

F2680
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DISASSEMBLY AND ASSEMBLY TM5-3-37
((D/A)
TRANSMISSION EX135W

5 Extract bushing and spring from

cylinder.

F2681

6 Remove the lever locking bolts.

F2682

7 Extract cylinder.

F2683

8 Check cylinder and sealing ring.

21599 60406991

F2684
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DISASSEMBLY AND ASSEMBLY TM5-3-38
((D/A)
TRANSMISSION EX135W

9 Using a press extract from pin

cylinder and the lever, checking the
snap ring on the pin.

F2685

3.1.7 REASSEMBLY OF GEAR UNIT CYLINDER

1 Insert lever in the cylinder and drive

in pin with the press with the snap
ring inserted in its housing.

F2686

2 Reinsert the cylinder, having

examined the sealing ring and the
correct position with care.
21599 60406991

F2683
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DISASSEMBLY AND ASSEMBLY TM5-3-39
((D/A)
TRANSMISSION EX135W

3 Reinsert screw using LOCTITE 242

with torque wrench setting M10 Nm
49 ÷ 51.

F2687

4 Position the unit cylinder vertically,

insert the spring and the threaded
bushing, screw up the tool (see photo
6 page 35). (75301372).

F2680

5 Screw up the threaded bushing until

the measurement taken before
disassembly is reached (if not taken
1 mm below the cylinder surface).

F2688

6 Reinsert screw using LOCTITE 242.

21599 60406991

F2689
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DISASSEMBLY AND ASSEMBLY TM5-3-40
((D/A)
TRANSMISSION EX135W

7 Tighten screws with torque wrench

setting M8 Nm 25 ÷ 26.

F2711

8 Ensure insertion of second gear (rod

at end of stroke left) before
remounting gear unit cylinder.

F2690

9 Remount and centre gear unit

cylinder on unit, using two special
screws. (75301371).

F2691

10 Using LOCTITE 510. Close with 2

screws opposite the pins, remove the
pin screws. Reinsert the other 2
screws with torque wrench setting M8
Nm 25 ÷ 26.
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F2580
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DISASSEMBLY AND ASSEMBLY TM5-3-41
((D/A)
TRANSMISSION EX135W

11 Connect a small hydraulic press max.

40 bar with manometer to the
cylinder.
Connect a tester lamp to the switch
to check its functioning.

F2692

12 Check with depth gauge, measuring

on the head of the screws and noting
the height.

F2693

13 Reinserting temporarily the screws,

turn the threaded bushing clockwise
3/4 of a turn.

F2694

14 Check the height again. It must be

0.5 ÷ 0.7 mm more than that noted in
item 12.
If more or less than 0.5 ÷ 0.7 mm ro-
tate the threaded bushing in order to
21599 60406991

obtain the correct heigth.

Repeat phases 17 - 18. If necessary
mark the new position of the threaded
bushing.

F2693
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DISASSEMBLY AND ASSEMBLY TM5-3-42
((D/A)
TRANSMISSION EX135W

15 Pressing the gear release lever and

applying a pressure of 35 bar - the
unit inserts first gear, bringing the
internal screw of the cylinder towards
the exterior (mm 21 ~).

F2695

16 Repeat the operation of phase 12.

F2696

17 Repeat the operation of phase 13 bur

turning the bushing anticlockwise
3/4 of a turn.

F2697

18 Repeat the operation of phase 14.

If in first gear position the height is
more or less, divide the height
between the first and the second.
Ex: Q 2a = 0.7 ÷ Q 1a 1.1 = 1.1 + 0.7
21599 60406991

= 1.8 : 2 = 0.9
Ex: Q 2a = 1 ÷ Q 1a 0.5 = 1 + 0.5 = 1.5
: 2 = 0.75

F2696
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DISASSEMBLY AND ASSEMBLY TM5-3-43
((D/A)
TRANSMISSION EX135W

19 Pay attention each time when

changing gear, pressing the release
lever, ascertain the brake is free,
ensure that the gear is inserted
completely.
If necessary rotate the input shaft or
the output shaft.

F2695

20 Check the functioning of the safety

switch (with torch or tester). With
gears inserted this must remain off.
It begins to turn on after the cylinder
has moved by mm 0,5 ÷ 1.5 - from
2nd to 1st or from 1st to 2nd gear. Switch
driving torque Nm 54.2 max.

F2693

21 Carry out all tests correctly. Remove

the screws, check the O-ring,
remount the cover and tighten the M8
screws with torque wrench setting 25
÷ 26 Nm.

F2698
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DISASSEMBLY AND ASSEMBLY TM5-3-44
((D/A)
TRANSMISSION EX135W

3.2 GEAR UNIT BROKEN, INSERTION OF 1st GEAR TO FINISH WORK

1 Remove screws.

F2675

2 Remove the two spacers. Reinsert tje

screws, press (see photo) the gear
release lever, holding down until the
screws are inserted at end of stroke.
Torque wrench setting Nm 49 ÷ 51.
Release lever. Repeat the operation
in reverse order to render the
transmission functional.

F2710

3.3 SPECIFIC TOOLS

P/N DESCRIPTION USE PAGE

75301367 Spacer Ring to determine shims 13

75301368 Seal mounting guide Assembly of output shaft seal ring 15

75301369 Ring mounting guide Assembly of O-rings and antiextrusion 16

rings on synchroniser rod
21599 60406991

75301370 Special spanner Disassembly/assembly of inlet shaft 18

ring nut 26

75301372 Puller Disassembly/assembly of gear 31

control cylinder 34

75301371 Centering screw (Q.ty 2) Assembly and centering of gear 35

control cylinder
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DISASSEMBLY AND ASSEMBLY AX5-4-1
(O/P)
AXLES EX135W

4. AXLES

4.1 REAR AXLE

The rear axle is mainly composed of: axle housing, differential and final drives. The transmission is flanged
to the rear axle.

Specifications:
Rigid axle complete with hydraulic gearbox, bevel gear ratio 15:32, planetary reduction ratio 1:6.
Hydraulic brake: wet disc (6 friction disc + 6 spacer plates each side).

4 2

6 6 1
21599 60406991

F7510

1 - Breather plug 4 - Final drive filler and level plug

2 - Filler and level check plug 6 - Brakes bleeding screw
3 - Oil drainage plug
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DISASSEMBLY AND ASSEMBLY AX5-4-2

(O/P)
AXLES EX135W

4.4.1 axle housing

The rear axle is composed of: a central housing (1), two intermediate covers (2) and two side arms (3).
Inside the intermediate covers (2) the seats for the cylinders of the braking system and the parking negative
brake are mounted.
The two side arms (3) are of a non steering type, and include the seat for the disc brakes and the side shafts
(4).

2
1

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4
3

F7511
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DISASSEMBLY AND ASSEMBLY AX5-4-3
(O/P)
AXLES EX135W

4.1.2 REAR DIFFERENTIAL

The differential has the purpose of changing the relative rotation speed of the two wheels (right and left) when
travelling in an non straight direction. The differential provides, also, a reduction of the r.p.m. input through
a bevel gear unit.

Fig. 1 - Rear differential

(Refer to the legenda on the next page).

1
2
3

4 5 9
11 6 8
10 7 7
8 6
9

5
10
9 11
8
7
6
5 12
3

9
8
7
6
5 15

2
1
22
26
23 16

20
14 14
21 13
25 17
24
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18
F7670

19
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DISASSEMBLY AND ASSEMBLY AX5-4-4

(O/P)
AXLES EX135W

Pos. Description Q.ty Pos. Description Q.ty

1 Screw TC 2 15 Bevel gear set 1

3 Taper roller bearing 2 16 Screw TC 4
2 Ring nut 2 17 Shim 0,10 mm 1
4 Differential carrier 1 17 Shim 0,15 mm 1
5 Lockring 4 17 Shim 0,20 mm 1
6 Lockring 4 17 Shim 0,40 mm 1
7 Pin 4 17 Shim 0,50 mm 1
8 Friction washer 4 18 O-ring 1
9 Planetary gear 4 19 Screw 12
10 Sun gear 2 20 Seal ring 1
11 Friction washer 2 21 Ring nut 1
12 Screw 12 22 Screw 14
13 Shim 0,20 mm 1 23 Cover 1
13 Shim 0,30 mm 1 24 Spacer 1
13 Shim 0,15 mm 1 25 O-ring 1
13 Shim 0,10 mm 1 26 Lockwasher 14
14 Taper roller bearing 2

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-5
(O/P)
AXLES EX135W

4.1.3 FINAL DRIVE

The final drive is of a planetary type and its function is to reduce appropriately the r.p.m. of the wheels with
respect to the output r.p.m. from the differential. The reduction unit is composed of a toothed drum, three
planetary gears and a solar gear mounted on the splined end of the axle shaft.

Fig. 2 - Planetary reduction ratio: 6.00

9-27
12 8
7 21
26

10
11
12
13
14
15
25
24

16
17
18
19

20
23
1
17 28
18 22
19 F7671

Pos. Description Q.ty Pos. Description Q.ty

1 Washer-gasket 6 15 Support 2
2 Plug 4 16 Steel plate 2
3 Magnetic plug 2 17 Lockring 8
4 Arm 2 18 Planetary gear 8
5 Washer 32 19 Bearing 8
6 Screw 32 20 Nut 20
21599 60406991

7 Seal ring 2 21 Seal ring 2

8 Half shaft 2 22 Screw TE 4
9 Stud 16 23 Support 2
10 Hub 2 24 Nut 16
11 O-ring 1 25 Stud 16
12 Bearing 4 26 Friction washer 2
13 Lockring 2 27 Stud 4
14 Ring gear 2 28 Plug 1
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DISASSEMBLY AND ASSEMBLY AX5-4-6

(O/P)
AXLES EX135W

4.2. FRONT AXLE

The front axle is of a steering and swinging type.

The steering effect is obtained by an hydraulic cylinder acting on the two swivel knuckles (right and left) rotating
them depending upon the actuation direction of the steering wheel (front axle positioned in front of the
operator’s seat).
The swinging effect is obtained by two supports complete with bushings (2) mounted on the central housing
of the axle in turn secured to the lower frame of the machine.
The front axle is essentially composed of: an axle housing (A), containing the differential and the braking
system, a steering control cylinder (B), two final drives (C) mounted on the swivel knuckles.
Specifications:
Bevel gear set ratio 15:32, planetary reduction ratio 1:6.
Hydraulic brakes: wet discs (6 brake discs + 6 spacer plates each side).
Steering radius to the right 25°, to the left 26°11' with setting by stop screw.
Maximum swing of axle: ± 6°.

C 1 B

A 3

6 2 5 4
β
α

21599 60406991

F7672

A - Axle housing
B - Steering control cylinder 4 - Brakes bleeding screw
C - Final drive 5 - Hydraulic brakes control port
1 - Breather plug 6 - Final drive filler and level check plug
2 - Supports complete with bushings a - Steering angle to the right 25° 0'
3 - Filler and level check plug b - Steering angle to the left 26°11'
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DISASSEMBLY AND ASSEMBLY AX5-4-7
(O/P)
AXLES EX135W

4.2.1 AXLE HOUSING

The axle housing is composed of: two side arms (1), a central housing (2) two intermediate covers (3).
Between items (1) and (2) the two intermediate covers (3) containing the braking system are mounted.
The motion is transmitted from the differential contained inside central housing (2) to the final drives, through
two joints (4).

3
2

4
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F7673
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DISASSEMBLY AND ASSEMBLY AX5-4-8

(O/P)
AXLES EX135W

4.2.2 STEERING CONTROL CYLINDER

The front axle is equipped with a steering system controlled by an hydraulic cylinder inserted into the central
housing. Appropriate adjustable drag links (1) are screwed, on one side, directly onto the cylinder rod (2) and
on the other side are connected to the swivel knuckles.

F7674
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DISASSEMBLY AND ASSEMBLY AX5-4-9
(O/P)
AXLES EX135W

4.2.3 FRONT DIFFERENTIAL

The differential has the purpose of changing the relative rotation speed of the two wheels (right and left) when
travelling in an non straight direction. The differential provides, also, a reduction of the r.p.m. input through
a bevel gear unit.

Fig. 3 - Front differential

(Refer to the legenda on the next page).

7 8 24
3 12
11
13
14
10
9

24
12
11
13
14
4 10
5 9
6

15
4
24 5
12
11 14
13 13
14 11
12
24

16
17
18
2
16 7
19 3
20
21

22
1
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23 F7675
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DISASSEMBLY AND ASSEMBLY AX5-4-10

(O/P)
AXLES EX135W

Pos. Description Q.ty Pos. Description Q.ty

1 O-ring 1 21 Friction washer 4

2 Shim 1 22 Planetary gear 4
2 Shim 1 23 Differential case 1
2 Shim 1 24 Taper roller bearing 2
2 Shim 1 25 Shim 1
2 Shim 1 25 Shim 1
11 Bevel gear set 1 25 Shim 1
12 Taper roller bearing 2 25 Shim 1
13 Ring nut 2 26 Spacer 1
14 Screw TE 4 27 Ring nut 1
15 Screw TE 2 28 Seal ring 1
16 Screw 12 29 Protection ring 1
17 Friction washer 2 30 Flange 1
18 Sun gear 2 31 Nut 1
19 Pin 4 32 Lockring 4
20 Lockring 4

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-11
(O/P)
AXLES EX135W

4.2.4 FINAL DRIVE (SWIVEL KNUCKLE)

The final drive is of a planetary type and its function is to reduce in an appropriate manner, the r.p.m. of the
drive wheels with respect to the r.p.m. output of the differential. The reduction unit is composed of a toothed
hub, three planetary gears and a solar gear splined on the end of the axle shaft.

Fig. 4 - Planetary reduction ratio: 6.00

(Refer to the legenda on the next page).

13
12 13 10
11 48 14
14 12
10 11
9
8 WITH BUSH SOLUTION

15
18 27
5 19 26
6 4 16
20
21
23
17
28
7 43
3 29 42
2 30
6 WITH DOWEL BUSH
5
32
24 34
23 30
46 44
45 22
25 4 31-49
20
19

47
36
37
38
41
39
1

34
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35
42
43
36
37
38 2
40
F7676
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DISASSEMBLY AND ASSEMBLY AX5-4-12

(O/P)
AXLES EX135W

Pos. Description Q.ty Pos. Description Q.ty

1 Washer-gasket 6 26 Seal ring 2

2 Plug 4 27 Dust excluder 2
3 Magnetic plug 2 28 Pivot case 1
4 Screw 24 29 Seal ring 2
5 Nut 2 30 Bearing 4
6 Steering adjust screw 2 31 Stud 16
7 Arm 2 32 Wheel hub 2
8 Screw 32 33 O-ring 2
9 Washer 32 34 Ring gear 2
10 Bushing 2 35 Ring gear support 2
11 Seal ring 2 36 Lockring 8
12 Bearing 2 37 Planetary gear 8
13 Lockring 2 38 Bearing 8
14 O-ring 2 39 Nut 20
15 Coupling 2 40 Screw TE 4
16 Bushing 2 41 Support 2
17 Outer ring 2 42 Stud 16
18 Cover 2 43 Nut 16
19 Plug 2 44 Lockring 2
20 Grease fitting 2 45 Adjusting screw 2
21 Pivot pin 2 46 Nut 2
22 Pivot pin 2 47 Steel plate 2
23 Seal ring 2 48 Lockring 2
24 Bearing 2 49 Stud 4
25 Pivot case 1

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-13
(O/P)
AXLES EX135W

4.3 BRAKING UNIT

The braking action is hydraulically actuated in both axles through wet discs.
The service brake circuit is actuated by the action exercised on the brake valve. The latter sends pressurised
hydraulic oil (70 bar) to the piston of the front and rear axle. These pistons, after overcoming the reaction of
the springs, keeping the drive plate in rest condition, ensure that the discs are pressed one against the other,
thus providing the braking action.
The service brake circuit can be applied, while the machine is standing, by pressing a switch located on the
steering column, that controls electrically, the brake valve; the braking action occurs, under these conditions,
in a non modulated manner and allows an optimised stability during digging operations. The application of the
work brake is signalled by an indicator located in correspondence with the actuating switch.

Front-rear axle brake system

4
3
3
4

5
2

F7677

2 - Brake piston
3 - Seal
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4 - Ring
5 - Brake discs
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DISASSEMBLY AND ASSEMBLY AX5-4-14

(O/P)
AXLES EX135W

NOTES:

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DISASSEMBLY AND ASSEMBLY AX5-4-1
(D/A)
AXLES EX135W

4. AXLES

4.1 DISASSEMBLY AND ASSEMBLY OF AXLES

In describing the operations below, it is supposed that, in some cases, the axle has already been removed
from the machine. Moreover, each one of them is finalised toward the maintenance or the replacement of the
parts more subject to wear, such the brake discs, differential, final drives etc..
During all operations, it is recommended that the appropriate special tools are used, facilitating the operation,
and ensuring, at the same time, that all machined surfaces are protected and the safety of workers is provided.
Prior to starting the disassembly of components it is recommended that a thorough cleaning of the axle is
provided, removing deposits and accumulation of grease, then draining the lubricants. All the mechanical
components removed, must be thoroughly cleaned with appropriate cleaners, then repaired or replaced, in
case they show signs of damage, excessive wear, cracks, seizing etc..
In particular, check the integrity of all moving (bearings, gears, bevel gear set, shafts) and sealing components
(O-Rings, seals) subject to higher stress and wear.
It is recommended, however, that the sealing components are replaced every time an overhaul or repair of
components is performed.
When assembled, rings and seal must be lubricated in the sealing contact area.
In the case of the bevel gear set, the replacement of one of the its gears requires the replacement of the other
one, as well.
During the assembly, all the prescribed clearances and pre-loads must be implemented.

WARNING - The weight of the front axle is about 457 kg

The weight of the rear axle is about 354 kg without transmission.
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DISASSEMBLY AND ASSEMBLY AX5-4-2
(D/A)
AXLES EX135W

Symbols

To complete the information relative to the operations for the disassembly and/or intervention on the axle, the
use of the symbols listed below is applied. They will aid, depending upon the intervention to be performed,
and will accompany each illustration.

Disassembly of sub-groups Remove - place is safe condition

Assembly of sub-groups Place safety, glue

(liquid compound)

Avoid damages to materials and

Disassembly of bulky components parts

Assembly of bulky components Mark prior to disassembly

(for re-assembly)

Warning, important information

Charge - fill (oil - lubricant)

Check appropriate values, i.e.

Drain oil, lubricant
torques, dimensions, pressures etc.

Stretch
T = special tools

Apply pressure into hydraulic

Follow installation direction
system

Check, visual inspection

Clean

Eventually re-usable
(replace if required) Lubricate

Replace every time assembly is

performed
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-3
(D/A)
AXLES EX135W

4.1 FRONT AXLE

4.1.1 CHEKING WEAR AND REPLACING THE

BRAKING DISKS
1
1 CAUTION! Perform all operations on
both arms.
Remove the oil-level plug (1).

F1240382

2 Apply the brakes and, keeping them

under pressure, check the linings “S“
between the disks using tool T1 .
Minimum “S“: 4.5 mm.

CAUTION! Replace the braking disks T1

and the intermediate disks on both sides
if necessary.

S
F1240383

3 Remove rhe swinging support (2) on the

side opposite the drive.

NOTA. If the bushing (17) is worm and

needs replacing, note down the assembly 2
17
side of the connection notch “A”.

F1240384

4 Disconnect the pins of the steering bars

from the steering case (See "HOW TO
REMOVE THE STEERING
CYLINDER").
21599 60406991

Sling the arm (3) to be removed and put 3

the rod under slight tension.

F1240385
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DISASSEMBLY AND ASSEMBLY AX5-4-4
(D/A)
AXLES EX135W

5 Unloose and remove the screws (4) and

the washers (5) that fix the arm (3) to the 4 5 6
central body (6).

3 F1240386

6 Remove the arm (3) together with the

pack of the braking disks (7).
Place the arm on a bench.
7

3
F1240387

7 Remove the braking disks (7) and note

down their order of assembly.

NOTE 1 - If the disks do not need

replacing, avoid switching their position.
2 - Extract the axle shaft (18).

18
7
F1240388

8 Remove the reversal springs (8) from the

piston (9). 8
9
NOTE. If the springs (8) are weak or
21599 60406991

deformed they must be replaced.

8
F1240389
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DISASSEMBLY AND ASSEMBLY AX5-4-5
(D/A)
AXLES EX135W

9 Remove the pin screws (10) guiding the

piston (8).
9
CAUTION! If the screws are to be
replaced, note down the different colours
for the different brake gap.
(See "HOW TO ASSEMBLE THE
BRAKING UNITS")

10
F1240390

10 Slowly introduce compressed air through

the connection of the braking circuit in
order to extract the entire piston.

CAUTION! Hold on to the piston as it may

be suddenly ejected and damaged.

9
F1240391

10
15
17
9
17 8
11
14 MAX 10°
16
2
1
3

13
12
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6 18

7
5
4
D1240037
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DISASSEMBLY AND ASSEMBLY AX5-4-6
(D/A)
AXLES EX135W

4.1.2 HOW TO ASSEMBLE THE BRAKING

UNITS 14
12
1 Accurately clean the piston (9) and the
11
seats of slide and seal.
Replace the O-rings (11) and (12) and 13
the anti-extrusion rings (13) and (14);
make sure that the assembly side is
correct.

CAUTION! Accurately check the 3

positioning of the anti-extrusion rings (13) 9
F1240392
and (14).

2 Insert the stroke automatic regulation

springs (9); place them in line with the
piston (15).

15

15 9
F1240393

3 Lubricate the seals (11) and (12) and fit

the piston (9) into the arm (3).
A
CAUTION! Make sure that the piston
seat fits into the stop pin (A) inside the
arm.

F1240394

4 Assist the insertion of the piston (9) by

lightly hammering around the edge with
a plastic hammer.
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F1240395
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DISASSEMBLY AND ASSEMBLY AX5-4-7
(D/A)
AXLES EX135W

5 Fit the pin screws (10) making sure that

they are all of the same colour. White: 1
10
mm gap
Yellow: 0.75 mm gap
Blue: 0.5 mm gap
Apply Loctite 270 to the thread.
Torque wrench setting: 5÷7 Nm.

F7632

6 Fit the reversal springs (8) on the piston

(9). 8
9
CAUTION! Pay due attention not to
deform the connections of the springs.

8
F1240389

7 Slightly lubricate the braking disks (7) and

fit them in the arm following the correct
sequence; orient them so that the oil
circulation holes and the marks “B” are B
perfectly lined up.

NOTA. When installing the steel discs,

the slot corresponding to the oil level cap
should be kept free.
7
F1240398

8 Check that the positioning of the sealing

ring (16) on the arm is intact; install the
complete arm.
Lock it into position using two facing
21599 60406991

screws (4) and washers (5).

16
F7633
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DISASSEMBLY AND ASSEMBLY AX5-4-8
(D/A)
AXLES EX135W

9 Check the flatness of the arms using tool

T2 and finally lock the arms with the
T2
screws (4) and the washer (5) using the
cross-tightening method.
Torque wrench setting: 298 Nm

F1240400

4.1.3 HOW REMOVE THE COMPLETE

STEERING CASE 1

1 Remove the guard (1) and disconnect the

articulation pin (2) (See "HOW TO
REMOVE THE STEERING
CYLINDER").

F1240425

2 Sling the entire unit (7) and connect it to

the hoist, putting the rod under light
tension. 7

F1240426

3 Unloose and remove the fittin screws (3)

from the bottom articulation pin (4).

NOTE. Screws cannot be re-used.

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3
F1240427
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DISASSEMBLY AND ASSEMBLY AX5-4-9
(D/A)
AXLES EX135W

4 Remove the bottom articulation pin (4)

5
complete with front sealing ring (5).

4
F1240428

5 AUnloose and remove the fittin screws

(3) from the top articulation pin (6).

F1240429

6 Using two levers, remove the top

articulation pin (6) complete with front
seal (5).
Pay attention not to damage the surfaces.
6
5

F1240430

7 Remove the complete steering case (7).

7
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F1240431
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DISASSEMBLY AND ASSEMBLY AX5-4-10
(D/A)
AXLES EX135W

8 Using a puller for inner parts, remove the

top bush (8) and the bottom ball-bush (9).

F1240432

9 Remove the articulation pins (4) and (6)

and the front sealing rings (5).
5
NOTE. Note down the side for assembly.

4 6

F1240569

10 If the ball cover (11) needs replacing,

remove it from the bottom articulation pin
(4).

11

F1240570

1
3
6
10
2 5
8
21599 60406991

9
5
3
4 D1240038
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DISASSEMBLY AND ASSEMBLY AX5-4-11
(D/A)
AXLES EX135W

4.1.4 HOW TO ASSEMBLE THE COMPLETE

STEERING CASE

1 If the bottom articulation pin (4) has been

extracted, position the pin under a press
11
and fit the ball cover (11).

F1240571

2 Fit the front sealing rings (5) onto the

articulation pins (4) and (6).
5
NOTE. Carefully check that the rings are
properly oriented (5).
4 6

F1240569

3 Lubricate the top bush (8) or the bottom

ball bush (9) and fit them into the fulcrum
holes of the arm.
Use tools T3 and T4. T3
9

8 T4

F1240433

4 Lubricate the terminal of the u-joint (10)

and install the steering case (7).
Pay due attention not to damage the dust
cover rings and the sealing rings.
7
21599 60406991

10
F7634
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DISASSEMBLY AND ASSEMBLY AX5-4-12
(D/A)
AXLES EX135W

5 Fit a new seal (5) onto the top articulation

pin (6). Lubricate and install the unit in
the steering case. Position the screws (3)
and lightly tighten.
Check the correct assembly side of the 6
seal (5). 5

F1240430

6 Fit a new seal (5) onto the bottom 5

articulation pin (4). Lubricate and fit the
unit in the sterring case. Position the
screws (3) and lightly tighten.
Check for the correct assembly side of
the seal (5).

4
F1240428

7 ighten the new fittin screws (3) of top and

bottom articulation pins in sequence
using the cross tightening method. 3
Torque wrench setting: 128±142 Nm

ITA
ITA 3
F1240436

8 Connect the articulation pin (2) (See

"HOW TO INSTALL THE STEERING 1
CYLINDER").
Lubricate articulations with Molikote and
21599 60406991

fit the dust cover (1).

F1240425
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DISASSEMBLY AND ASSEMBLY AX5-4-13
(D/A)
AXLES EX135W

4.1.5 HOW TO REMOVE THE U-JOINT

NOTE. The u-joint can only be removed after

extraction of the steering case has been
performed (See: "REMOVING THE
STEERING CASE"). Different procedures
need to be followed depending on the kind of
repair operation needed and the type of axle:
1 - Axle without parking brakes: compressed
air (7 bar approx.) should be introduced
in the braking circuit in order to hold the
braking disks in position.
2 - Axle with negative brake: does not
require any preparation as the disks are
mechanically locked in position.
3 - Axle with mechanical brake: requires that
the external control levers are put under
tension in relation to each other.
4 - Disassembly to be carried out with the
arm resting on the bench.
The explanations reported herewith refer to
removal operations carried out on the bench;
the different stages of u-joint removal alsoapply
to all other solutions or versions.

1 Unloose and remove the top and bottom

check nuts (2) from the dowels (3).

3
2

F1240365

4 Remove top and bottom check dowels

(3) from the flange (5) or bush (13).
21599 60406991

F1240366
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DISASSEMBLY AND ASSEMBLY AX5-4-14
(D/A)
AXLES EX135W

Flanged version

3 ERemove the u-joint (4).

NOTE. To remove the u-joint use, if

necessary, a plastic hammer or a lever.

F1240576

4 Remove the snap ring (9) from the

bearing as well as the packing ring (5).

9
F1240368

5 Position the entire u-joint (4) under a

press and remove the bearing (8) and the
ring (5) simultaneously. 4

F1240369

6 Extract the sealing ring of the shaft from

the flange (5).

NOTE. Note down the assembly side of

21599 60406991

the ring.

7
5

F1240370
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DISASSEMBLY AND ASSEMBLY AX5-4-15
(D/A)
AXLES EX135W

Coupling version

7 Remove the entire u-joint (4).

NOTE. To remove the u-joint use, if

necessary, a plastic hammer or a lever.

F1240367

8 Remove the snap ring (9) from the

bushing unit (13).

13

F1240371

9 Position the entire u-joint (4) under a

press and remove the complete bush
(13). 4

13

F1240375

10 Remove the snap ring (10) from the

bearing (11). Use a puller to remove the
bearing (11), the sealing ring (12) and the
O-ring (14).
21599 60406991

NOTE. Note down the assembly side of

the ring (12). 10
11 11 12

F1240372
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DISASSEMBLY AND ASSEMBLY AX5-4-16
(D/A)
AXLES EX135W

1 3

FLANGED VERSION
9
8
7
6
5

4
2

3 9
10
11
12
13
14
COUPLING VERSION
D1240039

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-17
(D/A)
AXLES EX135W

4.1.6 INSTALLATION OF U-JOINT

6 5
Flanged version

1 Insert the sealing ring (7) of the shaft in

the flange (5), using tool T5.
NOTE. Carefully check the assembly
side. Also replace the outer O-ring (6).
7

T5

F1240373

2 Fit the flange (5) onto the u-joint (4).

Heat the bearing (8) at an approx. tem-
perature of 100° C, fit it on the u-joint and
fasten.
4

5
8
F1240374

3 Fit the snap ring (9) on the bearing (8).

9
F1240368

Coupling version

4 Using tools T5 and T6, insert the sealing

ring (12) and the bearing (11) in the bush
21599 60406991

(13). T5 T6

NOTE. Carefully check the assembly side

of the seal (12).
12 11

13 13
F1240376
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DISASSEMBLY AND ASSEMBLY AX5-4-18
(D/A)
AXLES EX135W

5 Fit the snap ring (10) on the bearing (11).

10
11

F1240377

6 Heat the bearing in oil at an approx. tem-

perature of 100° C and fit the entire bush
(13) on the u-joint (4).

13

F1240378

7 Fit the check ring (9) on the bushing unit

(13); also put the O-ring (14) into position.
14 13

F7635

8 Insert the u-joint and tighten the top and

bottom dowels (2).
Torque wrench setting: Max. 15 Nm.
2
21599 60406991

NOTE. For u-joint coming with a bush,

centre the point of the check dowels in
the slot.

F1240379
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DISASSEMBLY AND ASSEMBLY AX5-4-19
(D/A)
AXLES EX135W

9 Apply Loctite 242 to the jutting parts of

the dowels (2).
2

F1240380

10 Screw the check nuts (3) of the dowels

(2) and lock them using a dynamometric
wrench.
Torque wrench setting: 122 Nm 3

F1240381

3 2 3 2

D1240082
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-20
(D/A)
AXLES EX135W

4.1.7 HOW TO DISASSEMBLEE THE

PLANETARY REDUCTION 1

1 Disconnect the steering bars from the

steering case (3).
For details, see "HOW TO REMOVE THE
COMPLETE STEERING CASE".
Remove the securing screws (1) from the 2
planetary carrier cover (2).

1
F1240437

2 Disjoint the planetary carrier cover (2)

from the steering case (3) by alternatively 3
forcing a screwdriver into the appropriate
slots.

F1240438

3 Remove the complete planetary carrier

cover (2). 2

F1240439

4 Unloose and remove the tightening nuts

(4) from the crown flange (5).
5
21599 60406991

4
F1240440
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DISASSEMBLY AND ASSEMBLY AX5-4-21
(D/A)
AXLES EX135W

5 Remove the safety flange (6).

F1240441
ITA

6 Using a puller, remove the complete

crown flange (5) by acting on the stud
5
bolts.

F1240442

7 Partially extract the hub (7) using a plastic

hammer.

NOTE. Alternately hammer on several 7

equidistant points.

F1240443

8 Remove the external bearing (8).

8
21599 60406991

F1240444
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DISASSEMBLY AND ASSEMBLY AX5-4-22
(D/A)
AXLES EX135W

9 By hand remove the complete hub (7).

7

F1240445

10 Remove the pins and remove the

steering case (3).
For details, see "HOW TO REMOVE THE
3
COMPLETE STEERING CASE".

F1240446

11 Remove the snap rings (9).

F1240447

12 With the help of a puller, remove the

planet wheel gears (10).
10
NOTE. Note down the assembly side of
21599 60406991

planet wheels.

F1240448
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DISASSEMBLY AND ASSEMBLY AX5-4-23
(D/A)
AXLES EX135W

13 Remove the snap ring (12) from the

crown (13).

12
13

F1240450

14 Remove the crown flange (5).

F1240451

15 Remove the sealing ring from the hub

(14).

14

F1240452

16 Remove the internal bearing (15).

21599 60406991

15

F1240453
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DISASSEMBLY AND ASSEMBLY AX5-4-24
(D/A)
AXLES EX135W

17 Remove the external thrust blocks from

the bearings (8) and (15) forcing a pin-
driver into the appropriate slots on the
hub (7).

NOTE. Hammer in an alternate way so

as to avoid crawling or deformation of the ITA
thrust blocks. ITA 7

F1240454

18 Use a puller to remove the centring ring

16
(16), the sealing ring (17) and the bearing
(18) from the steering case (3).
17
NOTE. Note down the orientation of both
centring ring (16) and sealing ring (17). 16 17 18
18

F1240455

19
16
18
3

17

14 12
15 5
9
10
8
21599 60406991

20
13 11
6
4
9
10
1
2 D1240040
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DISASSEMBLY AND ASSEMBLY AX5-4-25
(D/A)
AXLES EX135W

4.1.8 ASSEMBLING THE PLANETARY

REDUCTION 3 T7

1 Lubricate the bushing (18) and the seat

of the steering case (3).
Install the bushing (18), using tool T7.

18

F1240456

2 Lubricate the outer surface of the sealing

ring (17) and centring ring (16); fit them
into their seat using tool T8.

16 17 T8

F1240457

3 Position the lower part of tool T9A and

the thrust block of the external bearing
(8) under the press.

T9A

F1240458

4 Lubricate the seats of the bearings and

position the hub (7) on tool T9A; position
the thrust block of the internal bearing
(15).
21599 60406991

15
NOTE. Check that the thrust block is
correctly oriented.

T9A

F1240459
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DISASSEMBLY AND ASSEMBLY AX5-4-26
(D/A)
AXLES EX135W

5 Position the upper part of tool T9B and

press the thrust blocks into the hub (7)
all the way down.
T9B

F1240460

6 Fit the bearing (15) into the internal thrust

block.
15

F1240461

7 Apply a repositionable jointing compound

for seals to the outer surface of the
sealing ring (14). Position the sealing ring
(14) in the hub (7). 14

NOTE. Check that the ring (14) is 7

correctly oriented.

F1240462

8 Position tool T10 and press the sealing

ring (14) into its seat.

T10
21599 60406991

14

F1240463
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DISASSEMBLY AND ASSEMBLY AX5-4-27
(D/A)
AXLES EX135W

9 Insert the flange (5) in the crown (13).

13

F7636

10 Insert the snap ring (12) in order to fix

the flange (5) in the crown (13).

NOTE. Carefully check that ring (12) is

properly inserted in the slot of the crown 12
13
(13).

F1240465

11 With the help of tool T11, insert the planet

wheel gears (10) into the cover (2). T11
Accurately check the orientation.

10
F1240467

12 Lock the gears (10) into position by fitting

the snap rings (9).

9
21599 60406991

10
F7637
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DISASSEMBLY AND ASSEMBLY AX5-4-28
(D/A)
AXLES EX135W

13 Fit the steering case (3) onto the U-joint

(19) and install the articulation pins. For
pin assembly details, see "HOW TO
ASSEMBLE THE COMPLETE 3
STEERING CASE".

19
F7638

14 Connect the steering bars.

For details, see "HOW TO INSTALL THE
COMPLETE STEERING CASE".

F7639

15 Install the hub (7).

7

F1240445

16 Install the external bearing (8).

8
NOTE. Using a plastic hammer, drive the
bearing to the limit stop by lightly
21599 60406991

hammering around the edge.

F1240444
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DISASSEMBLY AND ASSEMBLY AX5-4-29
(D/A)
AXLES EX135W

17 Fit the complete crown flange (5).

NOTE. In order to fasten the flange (5), 5

use a plastic hammer and alternately
hammer on several equidistant points.

F1240470

18 Apply Tecnolube Seal 101 grease to the

surface of the safety flange (6) which
touches the crown flange (5). 6
Fit the safety flange (6). 5

F7640

Apply Loctite 242 to the studs and fit in

the nuts (4).

F1240472

20 Cross tighten the nuts (4) in two stages.

Initial torque wrench setting: 120 Nm 4
Final torque wrench setting: 255±285 Nm
21599 60406991

F1240473
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DISASSEMBLY AND ASSEMBLY AX5-4-30
(D/A)
AXLES EX135W

21 Fit the planetary carrier cover (2) onto the

hub (3). 20
3
CAUTION! Check that the O-ring (20) is
in good condition and in position.

2
F7641

22 Lock the planetary carrier cover (2) by

tightening the screws (1).
Torque wrench setting for screws: 40÷50 1
Nm

F1240475

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-31
(D/A)
AXLES EX135W

4.1.9 HOW TO REMOVE THE STEERING

CYLINDER
1
1 Remove the centring sensor (1) of the 2
steering piston (2), if supplied.

F1240401

2 Remove the safety cotter pins (3) from

the articulation pins (4) of the steering
bars (5).

CAUTION! Dispose of used cotter pins.

5

6
3

F1240402

3 Remove the castellated nuts (6) that lock

the articulation pins (4).
4

F1240403

4 Disconnect the tapered pins of the

articulation (4) from the steering case (7)
by means of a puller.

4 5
7
21599 60406991

F1240404
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DISASSEMBLY AND ASSEMBLY AX5-4-32
(D/A)
AXLES EX135W

5 If the connection of the steering bars

includes a safety collar (13), raise the
border. 13

F1240405

6 Disconnect left and right steering bars (5)

from the piston (2).
2

F1240406

7 Remove the securing screws (8) from the

9
steering cylinder (9).

F1240407

8 Extract the cylinder (9) using a plastic

hammer.

NOTE. For cylinder disassembly, refer to

21599 60406991

"HOW TO DISASSEMBLE THE 9

STEERING CYLINDER".

F1240408
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DISASSEMBLY AND ASSEMBLY AX5-4-33
(D/A)
AXLES EX135W

7 15

5 9
11

1 10 2
15
4

6 8
3

14 7
12

4
12
14
6 13
3

13
6
3

6
3 D1240041
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-34
(D/A)
AXLES EX135W

4.1.10 HOW TO INSTALL THE STEERING

CYLINDER
9
1 Check that the O-rings (15) of the axle
unit are in good condition; lubricate the
seats of the seals (15) and fit the steering
cylinder (9) into its seat.

F1240409

2 Lock the cylinder by cross- tightening the

screws (8). 9 8
Torque wrench setting: 116÷128 Nm

F1240410

3 Apply Loctite 242 to the thread and

connect the steering bars by screwing the 13
terminals onto the piston stem.
Torque wrench setting: 240÷270 Nm

NOTE. Versions with coupling require

that the rim of the articulation (13) is
riveted onto the surfaces of the piston
stem.

F1240411

4 Insert the pins (4) in the steering case

(7) and lock into position using a torque
wrench setting of 260÷290 Nm. 7
Find the position of the notching in
21599 60406991

relation to the hole of the cotter pins and

tighten the nut (6) further.
A
CAUTION! Check that rubber guards (A)
are intact.

F1240412
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DISASSEMBLY AND ASSEMBLY AX5-4-35
(D/A)
AXLES EX135W

5 Insert the cotter pins (3) and bend the

safety stems.

CAUTION! Use new cotter pins.

6 3

F1240413

6 Install the proximity (1) for checking

piston centring - if applicable - and tighten
the screws (10). 10
Torque wrench setting: 5÷6 Nm

F7642

7 CAUTION! Eliminate the action of the ne-

gative brake, if fitted.
Apply tools T12 to the hubs and lock T12
them.
Using a level “B”, check that tools are
T12
perfectly flat and parallel to each other.

F1240415

8 Connect the sensor (1) to the inspection

device according to either diagram.
1
21599 60406991

F1240416
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DISASSEMBLY AND ASSEMBLY AX5-4-36
(D/A)
AXLES EX135W

9 Sensor connection card, STANDARD I max=0,80 A

version.
NERO
BLACK

CONNETTORE
CONNECTOR

2 BLU
1 3
BLUE
--
4

BATTERIA
BATTERY

MARRONE
BROWN
+
2A
D1240029

I max=0,80 A
10 Sensor connection card, OPTIONAL
NERO
version. BLACK

CONNETTORE
CONNECTOR BATTERIA
2 BATTERY
BLU
1 3
BLUE
--
4

MARRONE
BROWN
+
2A
D1240030

11 Centre the piston by slowly moving it first

in one direction then in the other and = =
position it half way on the stroke, which
is determined by the switching on and off
of the signal lamp of the inspection device
in the reversal stage.

F1240550

12 Inspect jut “C” on one side of the piston

and note down the size for checking later
adjustments. C
21599 60406991

NOTE. If cylinders come without a

sensor, the centring of the piston must
be carried out on the basis of the
maximum stroke.

F1240418
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DISASSEMBLY AND ASSEMBLY AX5-4-37
(D/A)
AXLES EX135W

13 Without moving the piston, check front

and rear size at the edge of tools T12.
Max. difference: 0.6÷0.7 mm

NOTE. In order to check the rear size,

rotate the bevel pinion and check that
tools T12 are flat.

T12

T12
F1240419

14 If necessary, adjust convergency without

moving the centring of the piston and
adjust the length of the steering bars (5) 5 14
or (14).

NOTE. With a half turn of screw, the front

size is reduced by about 3 mm, whereas
the rear one is increased by about 3 mm.

F1240420

15 CONVERGENCY ADJUSTMENT ON
UNITS WITH COLLAR
Unloose the nuts on the collars (12). 12

F1240421

16 Rotate the ball-and-socket joints (16) until

convergency has been obtained.
Check that articulations move easily and 16
lock the collars (12).
21599 60406991

Torque wrench setting for nuts: 42÷ 52

Nm

F1240422
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DISASSEMBLY AND ASSEMBLY AX5-4-38
(D/A)
AXLES EX135W

17 CONVERGENCY ADJUSTMENT ON
ALTERNATIVE VERSIONS
Unloose the nuts (11) and screw them
15
onto the ball-and-socket joints (15). 11

F1240423

18 Hold the articulations still and rotate the

ball-and-socket joints (15). 15
Once the convergency has been 11
adjusted, lock the nuts (11).
Torque wrench setting for nuts: 298÷328
Nm

F1240424

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-39
(D/A)
AXLES EX135W

4.1.11 HOW TO DISASSEMBLE THE STEERING

CYLINDER 2

1 Remove the snap ring (1) from the

cylinder head (2).

F1240354

2 With the help of a plastic hammer, push

the head (2) inside the cylinder (3).
3
NOTE. The head should line up with the
edge of the cylinder.

F1240355

3 With the help of a drift, apply pressure to

the stop ring (4) that is placed inside the
cylinder (3) and extract the ring using a 3
screwdriver.

F1240356

4 Hammer the piston (5) on the rear of the

head (2) using a plastic hammer.
Continue hammering until the head (2)
is ejected from the cylinder (3).
21599 60406991

5
3
2
F1240357
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DISASSEMBLY AND ASSEMBLY AX5-4-40
(D/A)
AXLES EX135W

5 Disassemble the cylinder unit (3) by

extracting first the head (2), then the
piston (5). 5

CAUTION! Note down the assembly side 2

of the piston (5). The bevelled part “A” of
the piston is oriented towards the head
(2).
3

A F1240358

6 Remove all seals, anti-extrusion rings

and scraper rings from head (2), cylinder
(3) and piston (5).

NOTE.
1 - All seals must be replaced every time
the unit is disassembled.
2 - Particular attention must be paid not
to damage the seats of both seals
and piston slide

9
2
10
6
11 7
8
4
1

8
7
6
12
13
3
21599 60406991

D1240035
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DISASSEMBLY AND ASSEMBLY AX5-4-41
(D/A)
AXLES EX135W

4.1.12 HOW TO ASSEMBLE THE STEERING

CYLINDER
6 7 8
1 After applying grease, install the sealing
ring (6) of the shaft, the anti-extrusion ring
(7) and the scraper ring (8) inside the
cylinder (3).

CAUTION! Thoroughly check that

positioning of the anti-extrusion ring (7)
is correct.
D1240031

2 After applying grease, install the sealing

ring (6) of the shaft, the anti-extrusion ring
(7) and the scraper ring (8) in the head 8 7 6
(2).

CAUTION! Thoroughly check that

positioning of the anti-extrusion (7) ring
is correct.

D1240032

3 Fit the seal (9) onto the outside of the

head (2). 9
CAUTION!
1 - In order to facilitate assembly, apply
grease to the outer surface of the
piston.
2 - Do not roll the seal (9) up.

D1240033

4 Prepare the piston (5) by fitting it with the

guide ring (10), the magnetic ring (11),
the O-ring (12) and the seal (13). 11
13 10
21599 60406991

CAUTION!
1 - In order to facilitate assembly, apply
grease. 12 5
2 - If a centring sensor is not fitted, then
the magnetic ring (11) should be
replaced by another guide ring (10).

D1240034
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DISASSEMBLY AND ASSEMBLY AX5-4-42
(D/A)
AXLES EX135W

5 Apply tool T18 to the shaft on the

opposite side of the head (2) and centre
T18
it on the cylinder (3) so that it fits into the
piston (5). 5

NOTE. Apply a little grease to seals and

cylinder.
3

F1240359

6 Push the piston (5) into the cylinder for

100 mm using a plastic hammer.
5

3
F1240360

7 RRemove tool T18 and apply it to the

opposite side of the piston (5).
T18

5
2
F1240361

8 Apply grease to head (2) seals, fit the

head onto the piston and push it into the
cylinder (3) using a plastic hammer.
2
21599 60406991

NOTE. Insert the head as to line it up with T18

the edge of the cylinder.

5
F1240362
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DISASSEMBLY AND ASSEMBLY AX5-4-43
(D/A)
AXLES EX135W

9 Insert the stop ring (4) ensuring that it

fits into the seat of the cylinder (3). 4

3
F1240363

10 Apply pressure to the head using two

screwdrivers or levers until the head is
fastened onto the stop ring (4).

F1240364

11 Fit the snap ring (1) on the head (2).

2
CAUTION! Make sure that the snap ring
(1) is securely fastened in its seat.
If necessary, force it into its seat using a
drift and a hammer.

F1240354
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-44
(D/A)
AXLES EX135W

4.1.13 HOW TO REMOVE AND DISASSEMBLE

THE DIFFERENTIAL UNIT

Removing

1 Remove the complete arms.

For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS".

F7643

2 Mark the position of the ring nuts (1).

Remove the fittin screws (3) from the ring
nuts (1).
3

1
F1240478

3 Uniformly heat the ring nuts (1) up to a

temperature of 80° C.
1

F1240479

4 Apply tool T13 and remove the ring nuts.

NOTE. Accurately clean the threaded

portions on ring nuts of body and cover. T13
21599 60406991

F1240480
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DISASSEMBLY AND ASSEMBLY AX5-4-45
(D/A)
AXLES EX135W

5 Remove the fittin screws (4) from the

middle cover (5). 4 5

4
F1240481

6 Insert a screw-driver in the opposing slots

then force and remove the middle cover 6
5
(5) and the complete differential unit (6).

NOTE. Support the pieces using a rod.

F1240482

7 If the bearings need replacing, extract the

2 8
external thrust blocks of the bearings (7)
and (8) from middle cover (5) and central
body (2).

NOTE. Accurately check the O-ring (9). 7

5 9

F1240483

8 Remove the top plug (10).

10
21599 60406991

F1240484
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DISASSEMBLY AND ASSEMBLY AX5-4-46
(D/A)
AXLES EX135W

9 Remove the fittin screws (11) from the

crown (12).

11

12

F1240485

10 If the bearing need replacing, extract the

bearing (7) and remove the crown (12). 7

12

F1240486

11 Remove the shim washer (13) and the

planetary gear (14). 13

14

F1240487

12 If the bearing need replacing, extract the

bearing (8) from the differential carrier
(15).
21599 60406991

15

F1240488
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DISASSEMBLY AND ASSEMBLY AX5-4-47
(D/A)
AXLES EX135W

13 Remove the snap rings (16) from the two

pins (17) of the planet wheel gears (18).

16 17

F1240489

14 Insert tool T14 between the planet wheel

gears (18). T14

18 18

F1240490

15 Force tool T14 in-between the planet

wheel gears (18) using two pin-drivers.

CAUTION! Make sure that tool T14 is

perfectly lined up with the pins (17) when
locked.

15

F7644

16 Place the differential carrier (15) under a

press, position bush T15 and insert T16B
gudgeon T16A. Press T16A pin to limit
T15
position. T16B
21599 60406991

17

15

F1240492
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DISASSEMBLY AND ASSEMBLY AX5-4-48
(D/A)
AXLES EX135W

17 Remove gudgeon T16A and bush T15.

T16A
NOTE. In this condition the tool T14 T15
contains pin (17).

F1240493

18 Remove tool T14 together with the pin

(17) of the planet wheel.

15
17
F7644

19 Leave the released planetary gear in

position and again lock tool T14. T14
Repeat the operations for the extraction
of the pin of the 2nd planet wheel (17).
Repeat the operations for all other pins.

18 18

F1240490

20 Remove tool T14 and remove the last two

planet wheel gears (18), the 2 nd
differential unit gear (14) and the relative
14
shim washer (13) from the differential
21599 60406991

carrier.
13

15

F1240494
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DISASSEMBLY AND ASSEMBLY AX5-4-49
(D/A)
AXLES EX135W

4
3 5 16
1
20
9 11
17
19
20
17 16
19
18
13

14
7 13
15 10

12 18 8
2

19
17
20 19
16
17
20
6
16

3
1
D1240036
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-50
(D/A)
AXLES EX135W

4.1.14 HOW TO ASSEMBLE AND INSTALL THE

DIFFERENTIAL UNIT
14
Assembling

1 Insert the shim washer (13) and the 13

planetary gear (14) in the differential
carrier (15). 15

F1240494

2 Position the shim washer (19) and the

18
first planet wheel gear (18).
Hold them in position using bar T16C.
19

T16C

F1240495

3 With the help of gudgeon T16A, position

18
the second planet wheel gear (18) and
the relative shim washer (19).
T16A

19 15

T16C

F1240496

4 Insert tool T14 between the two planetary

gears (18). Line up the entire unit by
T14
pushing bar T16C all the way down until
gudgeon T16A is ejected.
21599 60406991

T16C

F1240497
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DISASSEMBLY AND ASSEMBLY AX5-4-51
(D/A)
AXLES EX135W

5 Lock tool T14 behind the planet wheel

gears (18). T14
After locking, remove bar T16C.

18 18

F1240490

6 Fit the snap rings (20) onto the pins (17).

20 17

F1240498

7 Place the differential carrier (15) under

the press, position bush T15 and insert
the planet wheel pin (17).
17
T15

F1240499

8 Put gudgeon T16B on top of the planet

wheel pin (17). T16B 17

T15
21599 60406991

T16B

17

F1240500
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DISASSEMBLY AND ASSEMBLY AX5-4-52
(D/A)
AXLES EX135W

9 Press T16B pin all the way down.

T16B
T15
T16B

17

15

F1240492

10 Remove gudgeon T16B, bush T15 and

fit the snap ring (16) on the pin (17).

CAUTION! Make sure that the snap ring

centres the seat and that it rests on the 16
surface of the differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle. 17

F1240502

11 Position the second planetary gear (14)

in the differential carrier (15). 14

15

F7811

12 Position the shim washer (13) on the

crown (12).
13
NOTE. In order to hold the shim washer
21599 60406991

(13) in position, apply grease to it.

12

F1240504
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DISASSEMBLY AND ASSEMBLY AX5-4-53
(D/A)
AXLES EX135W

13 Position the crown (12) on the differential

carrier (15) and lock it with screws (11)
applied with Loctite 242.
Torque wrench setting for screws:
128÷142 Nm 11 12

NOTE. Secure the screws using the

cross-tightening method.

15

F1240505

14 Install the bearings (7) and (8) using tool

T17.

T17 8
T17 7

F1240506

2
15 If the bearings are replaced, insert the
external thrust blocks in the middle cover
(5) and in the central body (2).

F1240507

1 9
Installing 5 2
16 Position the differential unit (6) in the
21599 60406991

central body (2) with the help of a bar

and fit the middle cover (5).

NOTE. Thoroughly check the state of the

O-ring (9) and make sure that the cover
is fitted with the oil discharge in the lower
position.
F7645
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DISASSEMBLY AND ASSEMBLY AX5-4-54
(D/A)
AXLES EX135W

17 Lock the middle cover (5) with screws (4).

Torque wrench setting for screw: 4
23.8÷26.2 Nm
5

4
4

F1240852

18 NOTE. If the ring nuts (1) are removed,

spread them with Loctite 242.

Tighten ring nuts on the crown side until T13

clearance between pinion and crown is
zero, then lock the crown; go back 1/4÷1/
2 turn.

F1240509

19 Pre-set the bearings by means of the ring

nut situated on the opposite side of the
crown, so as to increase pinion torque
up to 140÷210 Ncm. T19
CAUTION! If bearings are not new, check
the static torque; if bearings are new,
check the continuous torque.

F1240510

20 Introduce a comparator with rotary key

“A” through the top plug hole (10).
Position the comparator on the centre of 12 A
one of the teeth of the crown (12), pre-
21599 60406991

set it to 1 mm and reset it.

F1240511
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DISASSEMBLY AND ASSEMBLY AX5-4-55
(D/A)
AXLES EX135W

21 Manually move the crown (12) in both

directions in order to check the existing
backlash between the pinion and the A
crown.

F1240512

22 Adjust the backlash between the pinion

and the crown by unloosing one of the
ring nuts (1) and tightening the opposite
to compensate. T13
Normal backlash: see table.

F1240509

23 Difference between MIN and MAX

clearance for whole circumference
should not exceed 0.09 mm.

24 Apply Loctite 242 to the screws (3), fit

them into one of the two holes and 10
tighten.
Torque wrench setting: 23.8÷26.2 Nm
3
21599 60406991

Fit the top plug (10) after applying

repositionable jointing compound for
seals to the rims.

F1240513
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DISASSEMBLY AND ASSEMBLY AX5-4-56
(D/A)
AXLES EX135W

25 Re-install the complete arms.

For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS".
3

F1240385

4.1.15 HOW TO REMOVE THE BEVEL RINION

1 Remove the complete arms and the

differential unit.
For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS" and "REMOVING THE
DIFFERENTIAL UNIT".

F7646

2 If disassembly is awkward, heat the

check nut (1) of the flange (2) at 80°C. 2

NOTE. Heating is meant to unloose the 1

setting of Loctite on the nut (1).

F1240514

3 Position tool T20A (or T20B), so as to

avoid pinion rotation.
Unloose and remove the nut (1); also T20A
(T20B)
21599 60406991

remove the O-ring (3).

F1240515
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DISASSEMBLY AND ASSEMBLY AX5-4-57
(D/A)
AXLES EX135W

4 Remove the flange (2) complete with

guard (4) by means of a puller.

F1240516

5 Remove the swinging support (5).

5

F1240517

6 Remove the sealing ring (6).

F1240518

7 IPosition wrench T22 onto the ring nut

(7) and apply bar hold T21 to the pinion
(8).
Stop wrench T22 and rotate the pinion
21599 60406991

so as to release and remove the ring nut 7

(7).
NOTE. If disassembly proves awkward, T21
weld the ring nut at approx. 80°C.

T22
F1240519
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DISASSEMBLY AND ASSEMBLY AX5-4-58
(D/A)
AXLES EX135W

8 Apply blocks T23 and, with the help of a

puller, extract the pinion (8) complete with 12
the internal bearing (9), the distance T23
piece (10) and shims (11).

NOTE. The thrust blocks of the bearings 8

remain in the central body (12).

F1240520

9 Remove the pinion (8), shims (11) and

distance piece (10).
10
8

11

F7647

10 Using a puller and a press, remove the

inner bearing (9) from the pinion (8).

F1240578

11 Remove the thrust block of the external

bearing (13).
21599 60406991

13

F1240521
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DISASSEMBLY AND ASSEMBLY AX5-4-59
(D/A)
AXLES EX135W

12 Insert a drift in the appropriate holes and

remove the thrust block of the internal
bearing (9) as well as the shim washers
(14).

14

9
F1240522

14

12

10
13

6
5

11

7
3
1 4

2 D1240042
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-60
(D/A)
AXLES EX135W

4.1.16 INSTALLAZIONE E REGISTRAZIONE

PIGNONE CONICO

1 Using a surface plate, reset a centesimal DG

comparator “DG” and place it on the
measurement ring T24 (with a thickness
of 30.2 mm).
Preset the comparator to approx. 2 mm. T24

F1240523

2 Bring the internal bearing (9), complete

with its thrust block, under the comparator
“DG”.
Determine overall thickness “D” of the DG
bearing checking the discrepancy
between this size and the size of the
measurement ring.

CAUTION! Press the thrust block in the 9

centre and take several measurements
while rotating the thrust block.
F1240524

3 Partially insert the thrust block of the

external bearing (13).

13
T25C

T25A
F1240525

4 Install tension rod T25C, measurement

ring T24 and front guide tool T25A on
the thrust block of the external bearing
(13). T25B T24 T25C T25A
21599 60406991

13
F1240526
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DISASSEMBLY AND ASSEMBLY AX5-4-61
(D/A)
AXLES EX135W

5 Connect the tension rod to the press and

move the thrust block of the external
bearing (13) into its seat.
Disconnect the press and remove the
tension rod.

NOTE. Before starting the next stage,

make sure that the thrust block has been
completely inserted into its seat.

F1240527

6 Insert tool T26B complete with external

bearing (13), measurement ring T24 and
gauged ring nut T26C.
Manually tighten.
T26C T24 T26B
13

F1240528

7 Fit a centesimal comparator “DG1” with

long stem into bar T26A; when the bar
rests on two size- blocks “GB” of 57 mm, DG1
reset the comparator. T26A
Preset the comparator to approx. 2 mm
and reset.

GB

GB
F1240529

8 Lay bar T26A on gauged nut T26C and

take the size “A” at about 57 mm
corresponding to the maximum diameter
of arms centring. T26C
21599 60406991

T26A
A
F1240530
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DISASSEMBLY AND ASSEMBLY AX5-4-62
(D/A)
AXLES EX135W

9 Calculate size “B” which will be the first

T24
useful value for calculating the size of the T26C
shims (14) that are to be inserted under
the thrust block of the internal bearing (9).

R115
T26B

A
30.2 61

(61-A)+115+30.2=B B D1240070

10 Check the nominal size (X) marked on

the pinion and add or subtract the
indicated variation (Y) so as to obtain size 8
“Z”. X
e.g.: Z= 118 + 0.1 = 118.1
Z= 118 - 0.2 = 117.8

F1240531

11 Calculate size “C” which represents the

second value for calculating the size of
the shims “S” that are to be placed under
the thrust block of the internal bearing (9).

(14) S
D Z
C=Z+D C
D1240069

B-C=S
12 Calculate the difference between sizes 14
“B” and “C” so as to obtain the size “S” of
21599 60406991

the shim (14) that will go under the thrust

block of the internal bearing (9).

F7812
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DISASSEMBLY AND ASSEMBLY AX5-4-63
(D/A)
AXLES EX135W

13 IInsert shim “S” (14) and the thrust block

of the internal bearing (9) in the central
body.

NOTE. To hold shim “S” (14) in position,

apply grease.

14

9
F1240533

14 Position tool T25A and tension rod T25C.

Connect the tension rod to the press,
fasten the thrust block and then remove
the tools.

NOTE. Before going on to the next stage,

make sure that the thrust block has been
completely inserted.

T25C T25A

F1240534

15 Position tools T26C and T26B complete

with tapered bearings (9) and (13);
manually tighten until a rolling torque has
been obtained. T26C 9 13
T26B

F1240535

16 IInsert the stem of a depth comparator

“DDG” in either side hole of tool T26C;
reset the comparator with a presetting of DDG
approx. 3 mm.
21599 60406991

F1240536
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DISASSEMBLY AND ASSEMBLY AX5-4-64
(D/A)
AXLES EX135W

17 Remove the comparator and release

tools and bearings from the central body.
Re-install all and insert the distance piece
(10) between bearings (9) and (13); T26C 9
10 13
manually tighten the whole pack. T26B

F1240574

18 Insert depth comparator “DDG” into tool

T26B-T26C and measure variation “H” H
DDG
in relation to the zero setting performed
back at point d.

9 T26C

13

T26B

F1240537

19 The variation is to be added to a set value H+0,12÷ 0,13=S1

of 0.12÷0.13 mm., so as to obtain the size
of shim “S1” (11) which will be inserted 11 S1
between the external bearing (13) and
the distance piece (10) and
subsequently, to determine the preload
for the bearings.

F1240541

20 Position the internal bearing (9) and the

pinion (8) under a press; force the bearing
onto the pinion.
21599 60406991

F1240542
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DISASSEMBLY AND ASSEMBLY AX5-4-65
(D/A)
AXLES EX135W

21 Fit the pinion (8), shim “S1” (11) and

distance piece (10) in the main body (12). 12
10
NOTE. The finer shims must be placed 8
in- between the thicker ones.

11

F1240543

22 Insert the external bearing (13) in the

central body in order to complete the pack
arranged as in the figure. 9 11 10
13

F1240538

23 Connect the pinion (8) to the tie rod T28A

and T28B; connect the tie rod T28C (see
special tools) to the press and block.
8

F1240575

24 Apply Loctite 242 to the thread of the ring

nut (7) and screw the nut onto the pinion
(8).
21599 60406991

8
7

F1240539
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DISASSEMBLY AND ASSEMBLY AX5-4-66
(D/A)
AXLES EX135W

25 Apply special wrench T22 to the ring nut

(7) and bar-hold T21 to the pinion (8).
Lock the wrench T22 and rotate the
pinion using a dynamometric wrench, up T21
to a minimum required torque setting of
500 Nm.

T22
F1240540

26 Apply onto the pinion (8) the bar-hold and

with the help of a torque metre, check
the torque of the pinion (8).
Torque: 120÷170 Ncm
T19
CAUTION! If torque exceeds the
maximum value, then the size of shim
“S1” (11) between the bearing (13) and
the distance piece (10) needs to be
increased.
If torque does not reach the set value,
increase the torque setting of the ring nut
F1240510
(7) in different stages to obtain a
maximum value of 570 Nm.

CAUTION! If torque does not reach the

minimum value, then the size of shim “S1”
(11) needs to be reduced.

CAUTION! When calculating the

increase or decrease in size of shim “S1”,
bear in mind that a variation of shim (11)
of 0.01 mm corresponds to a variation of
60 Ncm in the torque of the pinion (8).

27 Lubricate the outer surface of the new

sealing ring (6) and fit it onto the central
body (12) using tool T27. 6
21599 60406991

T27 12
F1240545
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DISASSEMBLY AND ASSEMBLY AX5-4-67
(D/A)
AXLES EX135W

28 nstall the swinging support (5).

5
NOTE. Check that it is properly oriented.

F1240517

29 Fit the flange (2) complete with the guard

(4) and fasten it.
For keying the flange (2), use a plastic
hammer if necessary.

NOTE. Make sure that the guard (4) is

securely fastened onto the flange and
that it is not deformed.

2 4
F1240546

30 Apply Loctite 242 to the threaded part of

the pinion (8).
Position tool T20A (or T20B) and fasten
it in order to avoid rotation.
Insert O-ring (3) the nut (1) and tighten it
using a dynamometric wrench.
Torque wrench setting: 280÷310 Nm

T20A
(T20B)

F1240547

31 Remove blocks T23 (used for extracting

the pinion) and re-install the arms.
For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
21599 60406991

DISKS".

T23

F1240579
 Proteggere da
cementazione 50
0.8

10

Ø25

Ø50
Ø35 ---- 0.08
0.12
10 R5 1 1
4.3

32 32

4.5
1.5 x45°

0.8
3x15° 1.5x45° 3 x45°
Proteggere da
cementazione 30 20 10 150 32 32

R1
0.8

8
180 45°
45°

D1240044
T3
25 110 25

89
49.5
Ø30
DISASSEMBLY AND ASSEMBLY

160

D1240046

R1
T1

1.5

0
R2
Proteggere da

9
3x45°
cementazione 50

0.8
130

Ø67
Ø30
120± 0.1 200
155 = =
R7
.5 2 x45°

D1240048
+ 0.15
90

19 -- 0.4 10
= =

150

0.8
169

D1240045
AXLES EX135W

T6
T4
50 20

52 Proteggere da 0.8 0.8

0.8
cementazione 50
930

2 x45°
840

R1
.5
R1
0

Ø79
Ø30

R35

Ø54 + 00.1

Ø90 -- 0.15
Ø54,5 -- 00.1

Ø25
Ø64

Ø35

Ø50 ---- 0.1

0.2
0.8

0.8
3 x15°
5x15° 3x15°

0.8
0.8

3-- 00.2 7
2,5 -- 00.2
50 13 150
14 10 46 120± 0.1
213

D1240049
(D/A)

70
D1240043

D1240047

T7
T5
T2
AX5-4-68

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-69
(D/A)
AXLES EX135W

Ø75
T8 Ø158.5
Ø158.5 T9
Ø25
Ø50 H7 20° Ø35
Ø30

3x45°
0.8

16
50

0.8

R3
113
Ø132 -- 0.3
0.5

129
117
R3

--

148

102
cementazione
Proteggere da

R5 20°

100
150

25

R3

8x15°
Ø40
Ø140
233

Ø50---- 0.08
0.12
Ø150
0
R1

Ø200 ±0.03
3-- 00.2
13

Ø95
0.8
0.8
75

70

Ø35
5x15°
0.8

Ø50 ---- 0.1

0.2

Ø56
D1240058
Ø64 D1240050

Ø35
Ø40
T10 2x45° T11
2 x45°
120

175
1x45°

0.8
1---- 0.2
0.3
41

26
19

0.8 0.8
5.5

R3
5x15°
0.8

0
Ø139.5 -- 0.1
10 15

Ø153
0.8

25

Ø168
2x15°

Ø180 Ø39 0.8

D1260052
Ø50 D1260051

T12
R110
100

50
21599 60406991

R1
5 5x45°
27.5 ±0.2

55 500
555
17±0.1

Ø23
125

D1260053
125
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DISASSEMBLY AND ASSEMBLY AX5-4-70
(D/A)
AXLES EX135W

Ø125

10x15°
Ø35.5 ---- 0.1
0.2
T13 T14
Ø41
0.8

Ø25
Ø20 + 00.2
Ø15H7-n6

1x45°
100

Ø5.5
R1

0.8
Ø14
2 x15°

5
8
0.8

36

31
24
17
20

26
238

20
0
R1 Ø25
Ø10 0.8
Ø35
123

M26X1.5
125
33
36

Ø5.5
18

22.5
0.8
Ø37H7-n6

33

6 9
Ø47

10.5
1 x45°
6
Ø106 ± 0.1

0.8
R30

25

Ø20 + 00.2
Ø25
D1240054 Ø41 D1240055

24.5 6 0.0.1
T15 3x30° 2x30° T16
Ø28.5 ± 0.2

8.5
Ø19.9 +-- 0.1

Ø19.9 +-- 0.1

0
0.8

0
Ø30

5
15°

Ø6
10 46.45 ± 0.1 ± 0.5
10 19.6
Ø20 ++ 0.08
0.12
Ø27 ---- 0.1
0.2

56.6 29.6
Ø23

0.5x45°
Ø30

0.8
Ø19.9 +-- 0.1
0

D1240056

1x30°
175
D1240057

T17 Ø45 ---- 0.05

0.10 T18
1.5x45°

0.8

M8x1.25
R2 5°
0.8 .5
15
3

30
1

44
68

0.8
14
38

21599 60406991
75

6
7
1
0.8

1x45

30°
Ø38.5 ---- 0.1
0.2

Ø55
Ø63 Ø6.5

Ø65 D1240059
Ø20.4-- 00.05

Ø43.6 + 00.05
D1240072
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DISASSEMBLY AND ASSEMBLY AX5-4-71
(D/A)
AXLES EX135W

T19 Ø185 ± 0.2 T20

Ø105 ± 0.2
120

80
Ø75

Ø55 ---- 0.08

0.12

5x15
Tornito Ø
0.8

32,25 Ø105 ± 0.2

25
125

10
15
35
Ø10
125

25
60
15
14

Ø34.5+-- 00.2
48
59

Ø50
135 ±0.5
R5
30

M6
5

Ø20

97
73
Ø40H7-n6 1/4” 61.5

61.5
Ø44

85
126 12
Ø32 150
10
15
100

D1240060

Ø45 D1240061

T21 Ø85
Ø66
T22
Ø75
Ø55H7
Ø55 –– 0.08
0.12
0.8

0.8
5 x15

Tornito Ø
0.8

22

32,25
75

10
35
60

6
15

14
34

60
6
3/4"
Ø15H7-n6
20
21599 60406991

40
20

15°

60
100
275
D1240063 D1240064
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DISASSEMBLY AND ASSEMBLY AX5-4-72
(D/A)
AXLES EX135W

99.5
T23 Ø30.2 ± 0.001 T24

Ø17
5x45°
25

Ø88.8 ± 0.005
131

Ø42
20
D1240066
D1240065

T25
T25A
Ø19.55H7
21°

0.8
R5

R2
T25B
23
Ø83

Ø40
Ø88

3x15°
R2

0.8
0.8
Ø20 +-- 00.1

0.8 T25C T25B T25A

21°

Ø89 ---- 0.12

0.08
Ø55
Ø83
0.8

23 40 R2
73
0.8

R2

10 56
T25C 66
-- 0.08
-- 0.12

Ø16.5---- 0.2
0.1

M18x1.5
M18x1.5

473.5
Ø19.5

433.5
0.8 0.8 0.8
Ø35

Ø40
15°

5 5x15°
11 30
45
D1240067

T26 T27
4 x45°

Ø50
T26A
5x45°
15

14

40 300
63
87

Ø20 Ø110
74

M14 x1 T26B Ø65 R5

2 -- 0.2
0

M14 x1
12
20
25 25
50

0.02
61---- 0.01

0.8
12
R5

41
30

3x15°

21599 60406991
0.8

Ø41.2 +-- 0.03

0
Ø20
Ø37.75 ++ 0.08
0.8

0.12
195

Ø9
95

T26C Ø55 ---- 0.2

0.3
Ø11

35

Ø89
Ø80

Ø99
10
50

D1240073

Ø6.5
D1240075
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DISASSEMBLY AND ASSEMBLY AX5-4-73
(D/A)
AXLES EX135W

ENERPAC Mod. RCH-123

T28
T28C T28B T28A

23
3x15°

R2

0.8
64 0.8

0.8
R3

21°

Ø89 ---- 0.08

0.12
Ø55
Ø83
Ø40
Ø40H8
Ø70

Ø54

0.8 R2
R2

10 56
66

312
M18X1.5

M18X1.5
267
50 5x15° 0.8
0.8
15°

Ø40H8
R3
-- 0.2
-- 0
Ø19

17min.
30
D1240074

Ø28 ---- 0.08

0.12
T29 T31 T32
3x15°

Ø24 ---- 0.08

0.8

0.12 5x45°
10
0.8
15

Ø30
5x45°

65
cementazione
Proteggere da

50

30
30

cementazione
Proteggere da
110

130
140.5

5°
152
120

Ø26
3x45°

Ø33
R5

D1240093
0.5

2x45°

R5
15

0.8
3

0.8
T30
21599 60406991

M12x1.25
12 10
3x15°

15

Ø50
1

0.8
0.8
15

Ø64 + 0.2
18

0
0.8

2x15°

Ø84.5 Ø55 ---- 0.2

0.3
35

Ø94.5 Ø60
17

Ø110 Ø72 ---- 0.2

0.3

D1240097 D1240099

0
Ø16.2 -- 0.1

Ø17 ++ 0.2
0.1 D1240096

DISASSEMBLY AND ASSEMBLY
AXLES EX135W
TROUBLESHOOTING
Problem Cause
Overheatingbraking 1. Brake discs worn out
2. Incorrect brake fluid
3. Loss of brake fluid
4. Overheated axle causing brake
fluid to vaporize.
(Brake return when axle cools)
Soft brake pedal 5. Air in brake circuit
Ineffective safety 6. Incorrect adjustment
brake
7. Brake disc worn out
Overheating 8. Oil level wrong
9. Too small of a brake gap
10. Park brake dragging
11. Incorrect brake fluid in system
12. No free-pedal at master cylinder
13. Restriction in brake lines
14. Restriction in return line of brake
Servo system
15. Incorrect lubricant
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AX5-4-74
(D/A)
Correction
Inspect disc thickness and replace if necessary.
Replace all seals in axle and master cylinder that
have made contact with the incorrect fluid and all
brake hoses.
If incorrect fluid leaked into axle oil, seals and o-
rings in axle must be replaced.
Inspect for and repair any leaks in outside circuit
or master cylinder.
If caused by incorrect brake fluid see correction
N. 3.
If leak is to the outside replace the o-rings between
the center and intermediate housings.
If leak is to the inside replace above o-rings and
brake piston o-rings.
See "overheating" problem.
Bleed brakes as described in the vehicle’s service
manual.
See correction N. 1.
See correction N. 2.
Drain, flush and refill oil to proper level.
Readjust brakes to the specifications in the
vehicle’s service manual.
Unlock the brake and adjust the correct gap.
See correction N. 3.
Readjust brake pedal as described in the vehicle’s
service manual.
Inspect for and replace damage lines.
21599 60406991
Inspect for and replace damaged return line.
Change the retaining rings of the brake circuit and
brake pump.
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DISASSEMBLY AND ASSEMBLY AX5-4-75
(D/A)
AXLES EX135W

Problem Cause Correction

Diff-lock 16. If manual control, loose or Inspect and correct linkage and readjust as
inoperative misadjusted linkage indicated in vehicle’s service manual.

17. If hydraulic control, problems in Refer to the service manual for the vehicle.
the hydraulic or electrical circuits
of the vehicle

18. If hydraulic control: problems in Rebuilt cylinder.

actuating cylinder (noteable
through loss of hydraulic oil or
increase of the oillevel in axle)

19. If with lim. slip differential, worn Replace discs.

Oil coming out of 20. Leak in internal brake system See correction N. 2 and 3.
breather

21. Leak in diff-lock actuating cylinder See correction N. 19.

NoSpin indexing 22. Unequal tire pressure left anal Inflate tires to the recommended pressure in the
noise when driving right service manual, or until the rolling radius is equal.
straight.
CAUTION! With
NoSpin, fatigue 23. Different style, size or brand of Change tires to make the rolling radius equal.
damage can occur tires between left and right hand Vary the tire pressure within the specifications until
on the side with the side the rolling radius is equal.
larger tire.

Noise during coast 24. Wheel bearings damaged Replace and adjust.
and under power the
same

Noise under power 25. Low oil level Refill oil to proper level.
greater than during
coast 26. Incorrect lubricant See correction N. 16.

27. Ring and pinion worn Inspect through top cover. Replace and adjust.

28. Worn ring and pinion bearings Replace and adjust.

29. Worn planetary gears or bearings Replace.

21599 60406991

Noise during coast 30. Loose pinion nut Inspect ring, pinion and pinion bearings. If unda-
greater than under maged, retighten nut.
power
31. Only pinion bearing damaged See correction N. 29.

Noise during turn 32. Worn spider and/or side gears Replace.
(without NoSpin)
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DISASSEMBLY AND ASSEMBLY AX5-4-76
(D/A)
AXLES EX135W

Problem Cause Correction

A "Stick slip" noise 33. Worn or damaged cardanshaft Inspect and replace as described in vehicle’s
when going from service manual.
forward to reverse
34. Loose wheel Inspect for wheel and wheel stud damage.
Replace if needed and retorque lugnuts.

35. Articulation box joint and achsel Inspect and replace.

shaft damaged

36. Spider pins loose in diff-carrier Inspect through top cover. Replace.

37. Damaged or missing spider and/ See correction N. 33.

or side gear washers

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-77
(D/A)
AXLES EX135W

4.2 REAR AXLE

4.2.1 CHEKING WEAR AND REPLACING THE

1
BRAKING DISKS

1 CAUTION! Perform all operations on

both arms.
Remove the oil-level plug (1).

F1240601

2 Apply the brakes and, keeping them

under pressure, check the linings “S“
between the disks using tool T1 .
Minimum “S“: 4.5 mm. T1

CAUTION! Replace the braking disks

and the intermediate disks on both sides
if necessary.

S
F1240602

3 Unloose and remove the screws (3) and

the washers (4) that fix the arm (2) to the 3
central body (5).
2

F7648

4 Remove the arm (2) together with the

pack of the braking disks (6).
Place the arm on a bench.
21599 60406991

6
2 F1240603
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DISASSEMBLY AND ASSEMBLY AX5-4-78
(D/A)
AXLES EX135W

5 RRemove the braking disks (6) and note

down their order of assembly.

NOTE.
1 - If the disks do not need replacing,
avoid switching their position.
2 - Extract the axle shaft (9).

9
7
F7649

6 Remove the reversal springs (7) from the

7
piston (8).
8
NOTE. If the springs (7) are weak or
deformed they must be replaced.

7
F7650

7 Remove the pin screws (10) guiding the

piston (8).
8
CAUTION! If the screws are to be
replaced, note down the different colours
for the different brake gaps.
(See "HOW TO ASSEMBLE THE
BRAKING UNITS")

10
F7651

8 Slowly introduce compressed air through

the connection of the braking circuit in
order to extract the entire piston.
21599 60406991

CAUTION! Hold on to the piston as it may

be suddenly ejected and damaged.

8
F7652
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DISASSEMBLY AND ASSEMBLY AX5-4-79
(D/A)
AXLES EX135W

10
15

8
7
1 11
14 16

2
13
12
5 9

6
4
3
D1240076
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-80
(D/A)
AXLES EX135W

4.2.2 HOW TO ASSEMBLY THE BRAKING

UNITS
14
12
1 Accurately clean the piston (8) and the
11
seats of slide and seal.
Replace the O-rings (11) and (12) and 13
the anti-extrusion rings (13) and (14);
make sure that the assembly side is
correct.

CAUTION! Accurately check the 2

positioning of the anti-extrusion rings (13) 8
F7653
and (14).

2 Insert the stroke automatic regulation

springs (15); place them in line with the
piston (8).

15

15 8
F7654

3 Lubricate the seals (11) and (12) and fit

the piston (8) into the arm (2).
A
CAUTION! Make sure that the piston
seat fits into the stop pin “A” inside the
arm.

F7655

4 Assist the insertion of the piston (8) by

lightly hammering around the edge with
a plastic hammer.
21599 60406991

F7656
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DISASSEMBLY AND ASSEMBLY AX5-4-81
(D/A)
AXLES EX135W

5 Fit the pin screws (10) making sure that

they are all of the same colour. White: 1
mm gap
Yellow: 0.75 mm gap
Blue: 0.5 mm gap
Apply Loctite 270 to the thread.
Torque wrench setting: 5÷7 Nm.

10
F7657

6 Fit the reversal springs (7) on the piston

(8). 7
8
CAUTION! Pay due attention not to
deform the connections of the springs.

7
F7650

7 Slightly lubricate the braking disks (6) and

fit them in the arm following the correct
sequence; orient them so that the oil
circulation holes and the marks “B” are
B
perfectly lined up.

6
F7659

8 Check that the positioning of the sealing

ring (16) on the arm is intact; install the
complete arm (2). Lock it into position 16
using two facing screws (3) and washers
21599 60406991

(4).

2
F7660
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DISASSEMBLY AND ASSEMBLY AX5-4-82
(D/A)
AXLES EX135W

9 Check the flatness of the arms using tool

T2 and finally lock the arms with the T2
screws (3) and the washer (4) using the
cross- tightening method.
Torque wrench setting: 298 Nm

F1240703

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-83
(D/A)
AXLES EX135W

4.2.3 HOW TO DISASSEMBLE THE

PLANETARY REDUCTION AND AXLE
SHAFT

1 The axle shafts can only be removed after

extraction has been performed. Different
procedures need to be followed
depending on the kind of repair operation
needed and the type of axle:
1 - Axle without parking brakes:
compressed air (7 bar approx.)
should be introduced in the braking
circuit in order to hold the braking
disks in position.
2 - Axle with negative brake: does not
require any preparation as the disks
are mechanically locked in position.
3 - Axle with mechanical brake: requires
that the external control levers are put
under tension in relation to each
other.
4 - Disassembly to be carried out with
the arm resting on the bench.
The explanations reported herewith refer
to removal operations carried out on the
bench; the different stages of axle shaft
removal also apply to all other solutions
or versions.

4
10 16
13
17
3

7 11
8

14 12
21599 60406991

2
15

5
11
12
1
D1240081
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DISASSEMBLY AND ASSEMBLY AX5-4-84
(D/A)
AXLES EX135W

2 Remove the securing screws (1) from the

2
spider cover (2). 1

F1240604

3 Disjoin the spider cover (2) from the hub

(3) by alternatively forcing a screwdriver 2 3
into the appropriate slots.

F1240605

4 Remove the complete planetary carrier

cover (2). 2

F1240606

5 Remove the complete axle-shaft (4).

21599 60406991

F1240607
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DISASSEMBLY AND ASSEMBLY AX5-4-85
(D/A)
AXLES EX135W

6 Unloose and remove the tightening nuts

(5) from the crown flange (6). 5

6
F1240608

7 Remove the safety flange (7).

F1240609

8 Using and puller, remove the complete

crown flange (6) by acting on the stud 6
bolts.

F1240610

9 Partially extract the hub (3) using a plastic

hammer.
3
NOTE. Alternately hammer on several
21599 60406991

equidistant points.

F1240611
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DISASSEMBLY AND ASSEMBLY AX5-4-86
(D/A)
AXLES EX135W

10 Remove the external bearing (8).

F1240612

11 Extract the hub (3).

3

10
F1240613

12 Remove snap ring (10) from the arm (9).

F1240614

13 Remove the snap rings (11).

21599 60406991

11

F1240615
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DISASSEMBLY AND ASSEMBLY AX5-4-87
(D/A)
AXLES EX135W

14 With the help of an puller, remove the

planet wheel gears (12).

NOTE. Note down the assembly side of 12

planet wheels.

F1240616

15 Using a puller for inner parts, remove

shim washer (13) from planetary cover
(2).
2

13

F1240617

16 Remove the snap ring (14) from the

crown (15).

14
15

F7658

17 Remove the crown flange (6).

21599 60406991

F7661
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DISASSEMBLY AND ASSEMBLY AX5-4-88
(D/A)
AXLES EX135W

18 Remove the sealing ring (16) from the

hub (3).

16
3

F7662

19 Remove the internal bearing (17).

17
17

F7663

20 Remove the external thrust blocks from

the bearings (8) and (17) forcing a pin-
driver into the appropriate slots on the
hub (3).

NOTE. Hammer in an alternate way so

as to avoid crawling or deformation of the
thrust blocks. 3

F7664
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-89
(D/A)
AXLES EX135W

4.2.4 ASSEMBLING THE PLANETARY

REDUCTION AND AXLE SHAFT

1 PPosition the lower part of tool T9A and

the thrust block of the external bearing 8
(8) under the press.

T9A

F1240458

2 Lubricate the seats of the bearings and

position the hub (3) on tool T9A; position
the thrust block of the internal bearing
(17).
3 17
NOTE. Check that the thrust block is
correctly oriented.

T9A

F7665

3 Position the upper part of tool T9B and

press the thrust blocks into the hub (3)
all the way down.
T9B

F7666

4 Fit the bearing (15) into the internal thrust

block.
17
21599 60406991

F7667
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DISASSEMBLY AND ASSEMBLY AX5-4-90
(D/A)
AXLES EX135W

5 Apply a sealant for removable seals to

the outer surface of the sealing ring (16).
Position the sealing ring (16) in the hub
(3). 16

NOTE. Check that the ring (16) is 3

correctly oriented.

F7668

6 Position tool T10 and press the sealing

ring (16) into its seat.
T10

16

F7669

7 Insert the flange (6) in the crown (15).

15

F7698

8 Insert the snap ring (14) in order to fix

the flange (6) in the crown (15).

NOTE. Carefully check that ring (14) is

21599 60406991

properly inserted in the slot of the crown 14

15
(15).

F7699
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DISASSEMBLY AND ASSEMBLY AX5-4-91
(D/A)
AXLES EX135W

9 Using tool T33, fit shim washer (13) into

planetary cover (2).
T33
2

13
F1240618

10 With the help of tool T11, insert the planet

wheel gears (12) into the cover (2).
Accurately check the orientation.
T11
2

12
F1240619

11 Lock the gears (12) into position by fitting

the snap rings (11).

12

11

F7700

12 Lubricate the outer face of the sealing

ring (10) and, with the help of tool T34, fit
it in the arm.
T 34
NOTE. Accurately check direction of
21599 60406991

assembly.

F1240620
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DISASSEMBLY AND ASSEMBLY AX5-4-92
(D/A)
AXLES EX135W

13 Lubricate with grease the sealing ring

(16) and the hub of the arm (9). 3
Install the hub (3). 9

16

10
F7701

14 Install the external bearing (8).

NOTE. Using a plastic hammer, drive the 8

bearing to the limit stop by lightly
hammering around the edge.

F1240612

15 Fit the complete crown flange (6).

6
NOTE. In order to fasten the flange (6),
use a plastic hammer and alternately
hammer on several equidistant points.

F1240621

16 Apply Tecnolube Seal 101 grease to the

surface of the safety flange (7) which 6
touches the crown flange (6). 7
Fit the safety flange (7).
21599 60406991

F7702
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DISASSEMBLY AND ASSEMBLY AX5-4-93
(D/A)
AXLES EX135W

17 Apply Loctite 242 to the studs and fit in

the nuts (5).

F1240622

18 Cross tighten the nuts (5) in two stages.

Initial torque wrench setting: 130 Nm
Final torque wrench setting: 255÷285 Nm

F1240623

19 Grease snap ring (10) and sealing face

of axle-shaft (4).
Install the axle shaft (4) making sure it is
properly engaged in the braking disks
and in the differential unit.

NOTE. Be very careful not to damage the

snap ring (10).

F1240607

20 Fit the planetary carrier cover (2) onto the

hub (3). 2 3

CAUTION! Check that the O-ring (18) is

21599 60406991

in good condition and in position.

18
F7703
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DISASSEMBLY AND ASSEMBLY AX5-4-94
(D/A)
AXLES EX135W

21 Lock the planetary carrier cover (2) by

1 2
tightening the screws (1).
Torque wrench setting for screws: 40÷50
Nm

1 F1240624

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-95
(D/A)
AXLES EX135W

4.2.5 HOW TO REMOVE THE BEVEL PINION

1 ATTENTION! Though the photos in this

manual refer to a steering and oscillating
axle, the operations described apply
anyway.
Remove the complete arms and the
differential unit.
For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS" and "REMOVING THE
F1241060
DIFFERENTIAL UNIT".

2 If disassembly is awkward, heat the 2

check nut (1) of the flange (2) at 80°C.
1
NOTE. Heating is meant to unloose the
setting of Loctite on the nut (1).

F1240514

3 Position tool T20A (or T20B), so as to

avoid pinion rotation.
Unloose and remove the nut (1); also T20A
remove the O-ring (3). (T20B)

F1240515

4 Remove the flange (2) complete with

guard (4) by means of a puller.
21599 60406991

F1240516
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DISASSEMBLY AND ASSEMBLY AX5-4-96
(D/A)
AXLES EX135W

5 ATTENTION! This operation does not

apply to the fixed axle. 5

Remove the swinging support (5).

F1240517

6 Remove the sealing ring (6).

F1240518

7 IPosition wrench T22 onto the ring nut

(7) and apply bar hold T21 to the pinion
(8).
Stop wrench T22 and rotate the pinion
7
so as to release and remove the ring nut
(7).
T21
NOTE. If disassembly proves awkward,
weld the ring nut at approx. 80°C.

T22
F1240519

8 Apply blocks T23 and, with the help of a

puller, extract the pinion (8) complete with 12
the internal bearing (9), the distance T23
piece (10) and shims (11).
21599 60406991

NOTE. The thrust blocks of the bearings 8

remain in the central body (12).

F1240520
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DISASSEMBLY AND ASSEMBLY AX5-4-97
(D/A)
AXLES EX135W

9 Remove the pinion (8), shims (11) and

distance piece (10). 12
10
8

11

F1240543

10 Using a puller and a press, remove the

inner bearing (9) from the pinion (8).

F1240578

11 Remove the thrust block of the external

bearing (13).

13

F1240521

12 Insert a drift in the appropriate holes and

remove the thrust block of the internal
bearing (9) as well as the shim washers
(14).
21599 60406991

14

9
F1240522
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DISASSEMBLY AND ASSEMBLY AX5-4-98
(D/A)
AXLES EX135W

13 ONLY IF NECESSARY
Unloose and remove the screws (15) 15 16
locking the support (16); remove the
whole support.

F1241061

8
15
9
20 14

11

13 16
7
6
4
2
3 10
1

D1240109
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-99
(D/A)
AXLES EX135W

4.2.6 HOW TO INSTALL AND ADJUST THE

BEVEL PINION
16

1 ONLY IF HAS BEEN REMOVED

Fit support (16), including O-ring (20),
onto the intermediate body.

NOTE.
1 - The cavity located on the outer
diameter must faee upwards.
2 - Check and lubricate the O-ring (20).
F1241062

2 Fasten support with screws (15)

previously coated with Loctite 270.
Tighten using the criss-cross method to
a tightening torque of 90 ÷100 Nm. 15

F1241063

3 Using a surface plate, reset a centesimal

comparator “DG” and place it on the
measurement ring T24 (with a thickness
of 30.2 mm).
DG
Preset the comparator to approx. 2 mm.

T24

F1240523

4 Bring the internal bearing (9), complete

with its thrust block, under the comparator
“DG”.
Determine overall thickness “D” of the DG
21599 60406991

bearing checking the discrepancy

between this size and the size of the
measurement ring.

CAUTION! Press the thrust block in the 9

centre and take several measurements
while rotating the thrust block.

F1240524
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DISASSEMBLY AND ASSEMBLY AX5-4-100
(D/A)
AXLES EX135W

5 Partially insert the thrust block of the

external bearing (13).

13
T25C

T25A
F1240525

6 Install tension rod T25C, measurement

ring T24 and front guide tool T25A on
the thrust block of the external bearing
(13). T25B T24 T25C T25A

13
F1240526

7 Connect the tension rod to the press and

move the thrust block of the external
bearing (13) into its seat.
Disconnect the press and remove the
tension rod.

NOTE. Before starting the next stage,

make sure that the thrust block has been
completely inserted into its seat.

F1240527

8 Insert tool T26B complete with external

bearing (13), measurement ring T24 and
gauged ring nut T26C.
Manually tighten.
21599 60406991

T26C T24 T26B

13

F1240528
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DISASSEMBLY AND ASSEMBLY AX5-4-101
(D/A)
AXLES EX135W

9 Fit a centesimal comparator “DG1” with

long stem into bar T26A; when the bar
rests on two size- blocks “GB” of 57 mm, DG1
reset the comparator. T26A
Preset the comparator to approx. 2 mm
and reset.

GB

GB
F1240529

10 Lay bar T26A on gauged nut T26C and

take the size “A” at about 57 mm
corresponding to the maximum diameter
of arms centring. T26C

T26A
A
F1240530

11 Calculate size “B” which will be the first

T24
useful value for calculating the size of the T26C
shims (14) that are to be inserted under
the thrust block of the internal bearing (9).
R115

T26B

A
30.2 61

(61-A)+115+30.2=B B D1240070

12 Check the nominal size (X) marked on

the pinion and add or subtract the
indicated variation (Y) so as to obtain size 8
“Z”. X
21599 60406991

e.g.: Z= 118 + 0.1 = 118.1

Z= 118 ± 0.2 = 117.8

F1240531
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DISASSEMBLY AND ASSEMBLY AX5-4-102
(D/A)
AXLES EX135W

13 Calculate size “C” which represents the

second value for calculating the size of
the shims “S” that are to be placed under
the thrust block of the internal bearing (9).

(14) S
D Z
C=Z+D C
D1240069

14 Calculate the difference between sizes

B-C=S
“B” and “C” so as to obtain the size “S” of
the shim (14) that will go under the thrust 14
block of the internal bearing (9).

F7812

15 Insert shim “S” (14) and the thrust block

of the internal bearing (9) in the central
body.

NOTE. To hold shim “S” (14) in position,

apply grease.

14

9
F1240533

16 Position tool T25A and tension rod T25C.

Connect the tension rod to the press,
fasten the thrust block and then remove
the tools.
21599 60406991

NOTE. Before going on to the next stage,

make sure that the thrust block has been
completely inserted.

T25C T25A

F1240534
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DISASSEMBLY AND ASSEMBLY AX5-4-103
(D/A)
AXLES EX135W

17 Position tools T26C and T26B complete

with tapered bearings (9) and (13);
manually tighten until a rolling torque has
been obtained. T26C 9 13
T26B

F1240535

18 Insert the stem of a depth comparator

“DDG” in either side hole of tool T26C;
reset the comparator with a presetting of DDG
approx. 3 mm.

F1240536

19 Remove the comparator and release

tools and bearings from the central body.
Re-install all and insert the distance piece
(10) between bearings (9) and (13); T26C 9
10 13
manually tighten the whole pack. T26B

F1240574

20 IInsert depth comparator “DDG” into tool

T26B-T26C and measure variation “H” H
DDG
in relation to the zero setting performed
back at point d.
21599 60406991

9 T26C

13

T26B

F1240537
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DISASSEMBLY AND ASSEMBLY AX5-4-104
(D/A)
AXLES EX135W

21 The variation is to be added to a set value H+0,12÷ 0,13=S1

of 0.12÷0.13 mm., so as to obtain the size
of shim “S1” (11) which will be inserted 11 S1
between the external bearing (13) and
the distance piece (10) and
subsequently, to determine the preload
for the bearings.

F1240541

22 Position the internal bearing (9) and the

pinion (8) under a press; force the bearing
onto the pinion.

F1240542

23 Fit the pinion (8), shim “S1” (11) and

distance piece (10) in the main body (12). 12
10
NOTE. The finer shims must be placed 8
in- between the thicker ones.

11

F1240543

24 Insert the external bearing (13) in the

central body in order to complete the pack
arranged as in the figure.
9 11 10
21599 60406991

13

F1240538
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DISASSEMBLY AND ASSEMBLY AX5-4-105
(D/A)
AXLES EX135W

25 Connect the pinion (8) to the tie rod T28A

and T28B; connect the tie rod T28C (see
special tools) to the press and block.
8

F1240575

26 Apply Loctite 242 to the thread of the ring

nut (7) and screw the nut onto the pinion
(8).

8
7

F1240539

27 Apply special wrench T22 to the ring nut

(7) and bar-hold T21 to the pinion (8).
Lock the wrench T22 and rotate the
pinion using a dynamometric wrench, up
to a minimum required torque setting of T21
500 Nm.

T22
F1240540
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DISASSEMBLY AND ASSEMBLY AX5-4-106
(D/A)
AXLES EX135W

28 Apply onto the pinion (8) the bar-hold and

with the help of a torque metre, check
the torque of the pinion (8).
Torque: 120±170 Ncm
T19
CAUTION! If torque exceeds the
maximum value, then the size of shim
“S1” (11) between the bearing (13) and
the distance piece (10) needs to be
increased.
If torque does not reach the set value,
increase the torque setting of the ring nut
(7) in different stages to obtain a
F1240510
maximum value of 570 Nm.
CAUTION! If torque does not reach the
minimum value, then the size of shim “S1”
(11) needs to be reduced.
CAUTION! When calculating the
increase or decrease in size of shim “S1”,
bear in mind that a variation of shim (11)
of 0.01 mm corresponds to a variation of
60 Ncm in the torque of the pinion (8).

29 Lubricate the outer surface of the new

sealing ring (6) and fit it onto the central
body (12) using tool T27. 6

T27 12
F1240545

30 ATTENTION! This operation does not

apply to the fixed axle. 5

NOTE. Check that it is properly oriented.

21599 60406991

F1240517
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DISASSEMBLY AND ASSEMBLY AX5-4-107
(D/A)
AXLES EX135W

31 Fit the flange (2) complete with the guard

(4) and fasten it.
For keying the flange (2), use a plastic
hammer if necessary.

NOTE. Make sure that the guard (4) is

securely fastened onto the flange and
that it is not deformed.

2 4
F1240546

32 Apply Loctite 242 to the threaded part of

the pinion (8).
Position tool T20A (or T20B) and fasten
it in order to avoid rotation.
Insert O-ring (3) the nut (1) and tighten it
using a dynamometric wrench.
Torque wrench setting: 280÷310 Nm

T20A
(T20B)

F1240547

33 Remove blocks T23 (used for extracting

the pinion) and re-install the arms.
For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS".

T23

F1240579
21599 60406991
 10
10
1.5 x45°
Protect from
Proteggere da
cementation 1 1
cementazione 30

R1
0.8 32 32
4.3

4.5
32 32

89
49.5
Ø30
45°
45°
25 110 25

R1
0
3x45° 160
T1

D1240046
DISASSEMBLY AND ASSEMBLY

0.8
130

155

D1240048
120± 0.1 200
= =

T6
90
= =
AXLES EX135W

52 Protect from
Proteggere da
cementation
cementazione 50 20
50
2 x45°
R1
.5
R1
0
930
840

Ø25
Ø64

Ø35

Ø50 ---- 0.1

0.2
0.8
5x15° 3x15°

0.8
3-- 00.2

50 13 150

213

D1240049
120± 0.1
D1240043

T7
T2
(D/A)
AX5-4-108

21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-109
(D/A)
AXLES EX135W

Ø158.5 T9
Ø158.5

Ø50 H7 20° Ø35

Ø30
0.8

16
0.8

R3
113
-- 0.3
-- 0.5

129
117
R3

148

102
Ø132
R5 20°

100
25

R3

8x15°
Ø40
Ø140
Ø50---- 0.08
0.12
Ø150
Ø200 ±0.03

Ø95

✽Ø148 For slewing ring TIMKEN

✽Ø150 For slewing ring KOYO

D1240058

T10 T11
Ø35
Ø40
2x45°
2 x45°
120

175
1x45°

0.8
1---- 0.2
0.3
41

26
19

R3

0.8 0.8
5.5

5x15°
0.8

0
Ø139.5 -- 0.1
10 15
0.8

25

Ø153
Ø168
2x15°

Ø39 0.8

Ø180 Ø50 D1260051

D1260052
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-110
(D/A)
AXLES EX135W

Ø125
T13 T14

10x15°
Ø41
Ø35.5 ---- 0.1
0.2 Ø25
0.8
Ø20 + 00.2

1x45°

Ø5.5
R1

0.8
Ø15H7-n6

100

5
Ø14
2 x15°

36
8

31
0.8

26

20
24
17
20
238
0
R1 Ø25 0.8

Ø10
M26X1.5
Ø35
123

125
33

Ø5.5
36

18

22.5
0.8

33

6 9
Ø37H7-n6

10.5
Ø47

1 x45°
6

0.8
Ø106 ± 0.1 Ø20 + 00.2
R30

25

Ø25
Ø41 D1240055

D1240054

T15 T16
24.5 6 0.0.1 3x30° 2x30°
Ø28.5 ± 0.2

-- 0.1

Ø19.9 +-- 0.1

+0

8.5

0
Ø19.9
0.8

Ø30

Ø6
15° 10 46.45 ± 0.1 ± 0.5
10 19.6
56.6
Ø20 ++ 0.08
0.12

29.6 0.5x45°
Ø27 ---- 0.1
0.2

Ø23
Ø30

0.8
Ø19.9 +-- 0.1
0

D1240056

1x30°
175
D1240057

T17
1.5x45°

0.8
3
1

68

0.8
21599 60406991
38
0.8

Ø38.5 ---- 0.2

0.1

Ø55
Ø63
Ø65 D1240059
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DISASSEMBLY AND ASSEMBLY AX5-4-111
(D/A)
AXLES EX135W

T19 Ø185 ± 0.2

T20

Ø105 ± 0.2
120

80
Ø75

Ø55 ---- 0.08

0.12

5x15
Tornito Ø
0.8

32,25 Ø105 ± 0.2

25
125

10
15
35
Ø10
125

25
60
15
14

Ø34.5--+ 00.2
48
59

Ø50
R5
30

135 ±0.5
M6
5

Ø20

97
73
Ø40H7-n6 1/4”
61.5

61.5
Ø44

85
126 12
Ø32 150
10
15
100

D1240060

Ø45 D1240061

T21 Ø85
Ø66
T22
Ø75
Ø55H7
Ø55 –– 0.08
0.12
0.8

0.8
5 x15

Tornito Ø
0.8

22

32,25
75

10
35
60

6
15

14
34

60
6
3/4"
Ø15H7-n6
20
21599 60406991

40
20

15°

60
100
275
D1240063
D1240064
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DISASSEMBLY AND ASSEMBLY AX5-4-112
(D/A)
AXLES EX135W

Ø30.2 ± 0.001
99.5 T23 T24

Ø17
5x45°
25

Ø88.8 ± 0.005
131

Ø42
20
D1240066
D1240065

T25A
T25
Ø19.55H7
21°

0.8
R5

R2
T25B
23
Ø83

Ø40
Ø88

3x15°
R2

0.8
0.8
Ø20 +-- 00.1

0.8 T25C T25B T25A

21°

Ø89 ---- 0.08

0.12
Ø55
Ø83
0.8

23 40 R2
73
0.8

R2

10 56
T25C 66
Ø19.5 ---- 0.08
0.12

Ø16.5---- 0.1
0.2

M18x1.5
M18x1.5

473.5
433.5
0.8 0.8 0.8
Ø35

Ø40
15°

5 5x15°
11 30
45
D1240067

T26 T27
4 x45°

T26A Ø50
5x45°
15

14

40 300
63
87

Ø20 Ø110
74

T26B Ø65 R5
M14 x1
2 -- 0.2
0

M14 x1
12
20
25 25

0.8
12
50

0.02
61---- 0.01
R5

41

3x15°
30

0.8

21599 60406991

Ø41.2 +-- 0.03

0
Ø37.75 ++ 0.08
0.8

Ø20 0.12
195

Ø9
95

T26C Ø55 ---- 0.2

0.3

Ø89
Ø11

35

Ø99
Ø80
10
50

D1240073

Ø6.5
D1240075
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DISASSEMBLY AND ASSEMBLY AX5-4-113
(D/A)
AXLES EX135W

T28
ENERPAC Mod. RCH-123 T28C T28B T28A

23
3x15°

R2

0.8
64 0.8

0.8
R3

21°

Ø89 ---- 0.08

0.12
Ø55
Ø83
Ø40
Ø40H8
Ø70

Ø54

0.8 R2
R2

10 56
66

312
M18X1.5

M18X1.5
267
50 5x15° 0.8
0.8
15°

Ø40H8
R3
-- 0.2
-- 0
Ø19

17min.
30
D1240074

Ø28 ---- 0.08

0.12 T29 T31
3x15°

Ø24 ---- 0.08

0.8

0.12
5x45°
10
0.8

65
15
Protect from
cementation
cementazione
da

50
Proteggere

30

110
140.5
120

3x45°

5°
R5

0.5

Ø26
Ø33 D1240093
15

0.8
3

0.8
3x15°

15
21599 60406991

Ø50
0.8

M12x1.25
T30 Ø64 + 0.2
0

Ø84.5
15
18

Ø94.5
Ø110
35

D1240097
17

Ø16.2 -- 00.1
Ø17 ++ 0.2
0.1 D1240096
 Protect from
Proteggere da
1 cementation
cementazione 30

0.8

Ø25

Ø45
Ø25
Ø19.8
R0
.5
3x45°

0.8
1.5x45°
DISASSEMBLY AND ASSEMBLY

7 130
3
140

D1240117
T33

10
AXLES EX135W

1.5 x45°
Protect from
Proteggere da
cementation
cementazione 30
R1

0.8
54.5
Ø30

45H7
R1
0

3x45°
0.8

6.5 130

136.5
D1240116
(D/A)

T34
AX5-4-114

21599 60406991
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DISASSEMBLY AND ASSEMBLY
AXLES EX135W
Problem Cause
Insufficient 1. Brake discs worn out
braking
2. Incorrect brake fluid
3. Loss of brake fluid
4. Overheated axle causing brake
fluid to vaporize.
(Brake return when axle cools)
Soft brake pedal 5. Air in brake circuit
Ineffective safety 6. Incorrect adjustment
brake
7. Brake disc worn out
Overheating 8. Oil level wrong
9. Too small of a brake gap
10. Park brake dragging
11. Incorrect brake fluid in system
12. No free-pedal at master cylinder
21599 60406991
13. Restriction in brake lines
14. Restriction in return line of brake
Servo system
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AX5-4-115
(D/A)
Correction
Inspect disc thickness and replace if necessary.
Replace all seals in axle and master cylinder that
have made contact with the incorrect fluid and all
brake hoses.
If incorrect fluid leaked into axle oil, seals and o-
rings in axle must be replaced.
Inspect for and repair any leaks in outside circuit
or master cylinder.
If caused by incorrect brake fluid see correction
N. 3.
If leak is to the outside replace the o-rings between
the center and intermediate housings.
If leak is to the inside replace above o-rings and
brake piston o-rings.
See "overheating" problem.
Bleed brakes as described in the vehicle’s service
manual.
See correction N. 1.
See correction N. 2.
Drain, flush and refill oil to proper level.
Readjust brakes to the specifications in the
vehicle’s service manual.
Unlock the brake and adjust the correct gap.
See correction N. 3.
Readjust brake pedal as described in the vehicle’s
service manual.
Inspect for and replace damage lines.
Inspect for and replace damaged return line.
Inspect for and remove any filter, tee’d in line or
any other source of back pressure from the return
line.
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DISASSEMBLY AND ASSEMBLY AX5-4-116
(D/A)
AXLES EX135W

Problem Cause Correction

15. Incorrect lubricant Change the retaining rings of the brake circuit and
brake pump.

Diff-lock inoperative 16. If manual control, loose or Inspect and correct linkage and readjust as
misadjusted linkage indicated in vehicle’s service manual.

17. If hydraulic control, problems in Refer to the service manual for the vehicle.
the hydraulic or electrical circuits
of the vehicle

18. If hydraulic control: problems in Rebuilt cylinder.

actuating cylinder (noteable
through loss of hydraulic oil or
increase of the oillevel in axle)

19. If with lim. slip differential, worn Replace discs.

discs

Oil coming out of 20. Leak in internal brake system See correction N. 2 and 3.
breather

21. Leak in diff-lock actuating cylinder See correction N. 19.

NoSpin indexing 22. Unequal tire pressure left anal Inflate tires to the recommended pressure in the
noise when driving right service manual, or until the rolling radius is equal.
straight
CAUTION! With
NoSpin, fatigue 23. Different style, size or brand of Change tires to make the rolling radius equal.
damage can occur tires between left and right hand Vary the tire pressure within the specifications until
on the side with the side the rolling radius is equal.
larger tire.

Noise during coast 24. Wheel bearings damaged Replace and adjust.
and under power the
same

Noise under power 25. Low oil level Refill oil to proper level.
greater than during
coast 26. Incorrect lubricant See correction N. 16.

27. Ring and pinion worn Inspect through top cover. Replace and adjust.

28. Worn ring and pinion bearings Replace and adjust.

21599 60406991

29. Worn planetary gears or bearings Replace.

Noise during coast 30. Loose pinion nut Inspect ring, pinion and pinion bearings. If
greater than under undamaged, retighten nut.
power

31. Only pinion bearing damaged See correction N. 29.

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DISASSEMBLY AND ASSEMBLY AX5-4-117
(D/A)
AXLES EX135W

Problem Cause Correction

Noise during turn 32. Worn spider and/or side gears Replace.
(without NoSpin)

A "Stick slip" noise 33. Worn or damaged cardanshaft Inspect and replace as described in vehicle’s
when going from service manual.
forward to reverse
34. Loose wheel Inspect for wheel and wheel stud damage. Replace
if needed and retorque lugnuts.
21599 60406991
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DISASSEMBLY AND ASSEMBLY AX5-4-118
(D/A)
AXLES EX135W

NOTES:

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OPERATION PRINCIPLE TS5-5-1

(O/P)
TRANSMISSION SHAFT EX135W

5. TRANSMISSION SHAFT

5. 1 TRANSMISSION SHAFT

The transmission shaft is a sliding cardanic joint fitted between the two axles. It is flange-mounted with one
end to the transmission output shaft and the other end to the front axle; and its function is to obtain the front
and rear wheel drive.
The transmission shaft is composed of a sliding joint shaft (1), two cardanic spider (2) and two flange forks
(3).

The transmission shaft is equipped with grease nipples (4) to allow the correct lubrication.

4
4

1 3
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OPERATION PRINCIPLE TS5-5-2

(O/P)
TRANSMISSION SHAFT EX135W

NOTES:

21599 60406991
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DISASSEMBLY AND ASSEMBLY TS5-5-1

(D/A)
TRANSMISSION SHAFT EX135W

5.1 DISASSEMBLY AND ASSEMBLY

5.1.1 DISASSEMBLY

1 After removing the transmission shaft, carry out

a thoroughly cleaning of all parts of the
assembly.

Note: As the shaft being a sliding joint, it is

advisable to mark with a piece of chalk the
position on the fork and on the shaft on both
sides.

2 Remove the greasing nipple from the spider

and lay the flange fork (1) on the jaws of a wise
in order to allow withdrawing of the spider from
the shaft (2).

3 Remove the safety spring rings and beat with

a mallet on the upper surface of the shaft. 3
Withdraw the bearing (3) and remove the shaft.
2

1
3

4 Lay spider pins on the jaws and beat on the

flange forks to withdraw the bearing.
21599 60406991

5 Repeat the procedure for the joint of opposite

side.
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DISASSEMBLY AND ASSEMBLY TS5-5-2
(D/A)
TRANSMISSION SHAFT EX135W

5.1.2 ASSEMBLY

1 Fix firmly the flange fork. Insert the spider on

the flange fork respecting the orientation of
the greasing nipple hole.

greasing
nipple hole

2 To insert correctly the bearing it is advisable

the use of a centring guide. In this way the
bearing can be driven correctly in the spider
pin.

3 Remove the centring guide and insert the

second bearing from opposite side. Install the pusher
safety spring rings.
bearing

4 Repeat the operation procedure 2 and 3 to

fix the spider to the shaft.

centring
guide

5 Reinstall the greasing nipple.

6 Repeat the above operation procedure for the

opposite side of the cardanic joint.
21599 60406991

7 Carry out the greasing. Apply the grease to

the nipples until is appears in each bearing
seal.
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INDEX EX135W - 6 - 1

SECTION 6 FRONT-END ATTACHMENT

INDEX

Group 1 - FRONT-END ATTACHMENT ......................................................................... FA6-1-1

1.1 Boom Assembly
1.2 Arm Assembly
1.3 Bucket Assembly
1.4 Front Pipings
1.5 Maintenance Standard

Group 2 - HYDRAULIC CYLINDERS O/P - D/A ........................................................... CY6-2-1

2.1 Construction and function - O/P
2.1 Disassembly and Assembly - D/A

Group 3 - PINS AND BUSHINGS .................................................................................. FA6-3-1

3.1 Specifications

O/P = OPERATIONAL PRINCIPLE

D/A = DISASSEMBLY and ASSEMBLY
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21599 60406991
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FA6-1-1

FRONT-END ATTACHMENTS EX135W

1. FRONT-END ATTACHMENT

1.1 BOOM ASSEMBLY

1.1.1 CONSTRUCTION

Boom assembly consists of boom with bushings and hinge pins for boom cylinders and arm cylinder. The
stoppers are welded on the boom except for the boom cylinder rod side.

1 9 8 8 1 2 3 4
8
8
3

4
1
3
2
4
2
4

10 7 5 1

10

5
1. Hinge pins
2. Stopper
3. Stopper pin
4. Ring
21599 60406991

5. Bushing
6. Spacer F7142
7. Dust seal
8. Shim
9. Digging cylinder (dipper)
10.Lifting cylinder
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FA6-1-2

FRONT-END ATTACHMENTS EX135W

SPECIFICATIONS

- Boom weight with bushings: .............. 730 kg

- Boom dimensions:

659
98
932

2691 1909
4600
428
100
388
273

536

F7678
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FA6-1-3

FRONT-END ATTACHMENTS EX135W

1.1.2 TRIPLE ARTICULATION VERSION

The triple articulation version consists of boom, positioner and arm, bushings and hinge pins for boom and
cylinders: boom (2), positioner and arm. Stoppers are welded to the arms (boom, positioner and dipper),
except for the rode side on the boom cylinders.

7 2 3

8
4
3
10
8 4

1 2 3 4

1 A

1 5 1

B 7

7 7

11

9 1 7 2 3 7

11
A. Positioner 4
B. Boom 7
1. Hinge pins
2. Stopper 7
3. Stopper pin
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4. Ring 6
5. Bushing 1
6. Spacer 5
7. Shim 5
8. Gasket
8 1 8
9. Stopper plate
10.Digging cylinder (dipper) F7178

11.Positioner cylinder
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FA6-1-4

FRONT-END ATTACHMENTS EX135W

Specifications

(1) BOOM

- Boom weight: ................................... 375 kg

- Boom dimensions:

1723

196
1950
139
428

274

536

F7679
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FA6-1-5

FRONT-END ATTACHMENTS EX135W

(2) POSITIONER

- Positioner weight: .................. 500 kg

- Positioner dimensions:

2278

234

107
3100 585
273

100

272
388

139

F7680
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FA6-1-6

FRONT-END ATTACHMENTS EX135W

1.2 ARM ASSEMBLY

1.2.1 CONSTRUCTION

Arm assembly consists of arm with bushings, links and hinge pins.
Type: 2.090 m - 2.490 m - 2.990 m
9
7 13

3 12

10 33
9
3
3 11
4
3
12
8

9
8
7
8
9

63
10 7
23 8

4
7
8 23

10 12
F7501
1
3
1
3
8

35
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1. Hinge pins 4. Spacer 7. Bushing 10.Pin

2. Stopper 5. Bucket (see 1.3) 8. Ring 11.Shim
3. Link group 6. Arm 9. Gasket 12.Grease nipple
(link rod, linkage)
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FA6-1-7

FRONT-END ATTACHMENTS EX135W

1.2.2 SPECIFICATIONS

- Dipstick weight: 2.090 m .................................................................................... 315 kg

40.4
R 23

267
220
340
2090 632

254
90

100
272

F7681

- Dipstick weight: 2.490 m .................................................................................. 352 kg

21.8
R 23
278.8
215

340
2490 637
254
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90
272

100

F7682
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FA6-1-8

FRONT-END ATTACHMENTS EX135W

- Dipstick weight: 2.990 m .................................................................................. 420 kg

685

18.7
R 23

240 252

100
340
2990 635
639

254
90

100
272

F7683

Tie rod unit

- Linkage weight: .............................................................................................................................. 21 kg

553
25

F7685

- Link rod weight: .............................................................................................................................. 38 kg

5 R6
R6 5
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475
78

F7684
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FA6-1-9

FRONT-END ATTACHMENTS EX135W

1.3 BUCKET ASSEMBLY

1.3.1 CONSTRUCTION

The bucket is of all-welded high-strength steel structure and provided with teeth and side cutter.

05
06
02
03
04

07
01

A
00 B
C

10
08
09

ITEM DESCRIPTION

00 BUCKET ASS.LY
00A ANGLE-RIGHT TO BE WELDED
00B BUCKET TOOTH SHANK TO BE WELDED
00C ANGLE-LEFT TO BE WELDED
01 SPACER
02 PLATE
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03 SHIM 1 mm
04 SHIM 0,5 mm
05 SCREW
06 LOCKWASHER
07 PIN
08 PIN
09 BUCKET TOOTH TIP
10 RING
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FA6-1-10

FRONT-END ATTACHMENTS EX135W

1.3.2 MAINTENANCE STANDARD

ADJUSTING THE BUCKET CLEARANCE

(1) Check the bucket clearance "a" if necessary adjust the shim as follows.

(2) Adjustment of bucket linkage (standard bucket).

This machine has a bucket adjustment system to take up play in the linkage.
When play in the linkage increases, remove shims as explained below. This will allow the bush (4) to move
to the right and take up the clearance "a" between the bush and the arm boss.

(i) Remove bolt (2) and ring (1).

(ii) Remove shims (3) according to the clearance "a".

(iii) Fit ring (1) to pin (5) and tighten bolt (2).

NOTE:

Bucket clearance "a" should not be adjusted below 0.5 mm.

(2) BOLT
(4) BUSH
BUCKET ARM END BOSS BUCKET
(5) PIN

PIN
CLEARANCE "a"

(1) RING
(3) SHIM
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CLEARANCE ADJUSTMENT
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FA6-1-11

FRONT-END ATTACHMENTS EX135W

1.4 FRONT PIPINGS

1.4.1 CONSTRUCTION

(1) CONTROL PIPINGS

Front control pipings consist of boom cylinder pipings, arm cylinder pipings, bucket cylinder pipings and hoses.

BUCKET
CYLINDER
ARM
CYLINDER

BOOM
CYLINDER
(RIGHT)

BOOM
CYLINDER
(LEFT)

MAIN
PIPINGS
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F7112
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FA6-1-12

FRONT-END ATTACHMENTS EX135W

(2) LUBRICATE PIPINGS

The lubricate pipings consist of pipings and hoses for lubricate the hinged parts.

ARM CYLINDER
BOTTOM SIDE
BOOM CYLINDER
ROD END

BOOM CYLINDER
ROD END

BOOM
CYLINDER (RIGHT)

ARM
CYLINDER

BOOM
CYLINDER
(LEFT)

BOOM
FOOT PIN
(LEFT)

BOOM
FOOT PIN
(RIGHT)

F7113
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FA6-1-13

FRONT-END ATTACHMENTS EX135W

1.4.2 TRIPLE ARTICULATION VERSION

(1) CONTROL PIPINGS

Front control pipings are pipings and hoses for boom, positioning, arm and bucket cylinders.

E C
F D

B
G A
H

I
L
F6950

BOOM CYLINDERS
- Boom cylinders control: line G - H for right cylinder
line I - L for left cylinder
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G
H
L
I F7115
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FA6-1-14

FRONT-END ATTACHMENTS EX135W

POSITIONING CYLINDER
- Positioning cylinder control: line C - D

D
C

F7116

FRONT ATTACHMENT CYLINDERS LOCKING COCKS

Cocks are installed in the hydraulic oil system on the

pipes connecting the control valve to the bottom side of
arm cylinder, to the bottom side of both boom cylinders,
to the top side of positioning cylinder, and to the top side,
side of bucket cylinder in order to lock the front attachment
for the on-road travelling position.
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FA6-1-15

FRONT-END ATTACHMENTS EX135W

ARM CYLINDER
- Arm cylinder control: line A - B and O - P

O
P

P A
O B

B
A
F7117

P
O
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F7118
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FA6-1-16

FRONT-END ATTACHMENTS EX135W

BUCKET CYLINDER
- Bucket cylinder control: line E - F, M - N and Q - R

M
N

E
F
F7119

R
Q

M
N

F7120

Q
R
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F7121
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FA6-1-17

FRONT-END ATTACHMENTS EX135W

(2) LUBRICATE PIPINGS

The lubricate pipings consist of pipings and hoses for lubricate the hinged parts.

9
8
7
6

5
4

3
2
1

F7122
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1. Hinge pin right side (boom) 6. Hinge pin right side (boom/positioning)
2. Hinge pin left side (arm) 7. Positioning cylinder (rod side)
3. Positioning cylinder (head side) 8. Arm cylinder (head side)
4. Left boom cylinder (rod side) 9. Hinge pin left side (boom/positioning)
5. Right boom cylinder (rod side)
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FA6-1-18

FRONT-END ATTACHMENTS EX135W

1.5 MAINTENANCE STANDARD

1.5.1 REMOVAL AND INSTALLATION OF THE

CYLINDERS

Remove bucket cylinder

1 Place the unit on level ground.

2 Put wooden block under the bucket cylinder.

F5439

3 Stop the engine, then press on top of exhaust

valve to release pressure in hydraulic tank.

F7453

4 Remove ring and stopper pin.

F6991
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5 Push out pin with bar and hammer.

F6992
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FA6-1-19

FRONT-END ATTACHMENTS EX135W

6 Fasten a wire to bucket cylinder to hold cylinder

rod.

F6993

7 Remove bucket cylinder hoses.

Install plugs to all side of pipings and hoses.

F6994

8 Hoist bucket cylinder.

F6995

9 Remove ring, stopper pin and pin, then, remove

bucket cylinder.

F6996
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FA6-1-20

FRONT-END ATTACHMENTS EX135W

Install bucket cylinder

1 Install bucket cylinder to the dipstick.

Align bucket cylinder with dipstick.

F6995

2 Install pin, stopper pin and ring.

F6996

3 Install bucket cylinder hoses to the cylinder.

Tightening torque: 180 Nm

F6997

4 Hoist bucket cylinder and links, then, align bucket

cylinder rod with links.

F7454

5 Install pin, stopper pin and ring.

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F7455
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FA6-1-21

FRONT-END ATTACHMENTS EX135W

Remove arm cylinder

1 Place the unit on level ground.

2 Put wooden block under the arm cylinder.

F5440

3 Stop the engine, then press on top of exhaust

valve to release pressure in hydraulic tank.

F7453

4 Remove ring and stopper pin.

F6998

5 Push out pin with bar and hammer.

21599 60406991

F6999
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FA6-1-22

FRONT-END ATTACHMENTS EX135W

6 Fasten wire to arm cylinder to hold cylinder rod.

F6993

7 Remove arm cylinder hoses.

Anstall plugs to all side of pipings and hoses.

F7000

8 Remove lubricate piping from the arm cylinder.

F7001

9 Hoist arm cylinder.

F7002

4
2
10 Remove ring (1), stopper pin (2) and pin (3), then, 4 1
remove arm cylinder and the shims (4).
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3
F7003
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FA6-1-23

FRONT-END ATTACHMENTS EX135W

Install arm cylinder

1 Install the cylinder to the articulated arm.

F7067

4
2 Install pin, stopper pin and ring.
2
4 1

3
F7003

3 Install lubricate piping to the arm cylinder.

F7001
4 Remove plugs from hoses. Install arm cylinder
hoses to the cylinder.

Tightening torque: 180 Nm

F7000
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5 Hoist cylinder, then, align cylinder rod with the

dipstick.

F7477
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FA6-1-24

FRONT-END ATTACHMENTS EX135W

6 Install pin, stopper pin and ring.

F7463

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FA6-1-25

FRONT-END ATTACHMENTS EX135W

Remove boom cylinder

1 Place the unit on level ground.

Stop the engine, then, loosen the air breather

cap to release pressure in hydraulic tank.

2 Remove lubricate piping from the boom

cylinders.

F5441

3 Hoist boom cylinder.

F7464

4 MONOBLOC BOOM VERSION

Remove ring, stopper pin and pin. Push pin with
bar and hammer far enought to remove cylinder
rod.

5 TRIPLE ARTICULATION VERSION

Remove the plate securing screws, then
withdraw the pin far enough to disconnect the
21599 60406991

cylinder from with a punch and hammer.

CAUTION
Be careful not to completely withdraw the pin, in order
to avoid the disconnection of boom and positioning
arms. F7465
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FA6-1-26

FRONT-END ATTACHMENTS EX135W

6 Lower boom cylinder to put it on stand.

Push pinion other direction and lower cylinder.
Fully lower cylinder.

F7466

7 Fasten wire to boom cylinder to hold cylinder

rod.

F7467

8 Remove boom cylinder hoses.

Install plugs to the hoses of boom cylinder and
to pipings.

F7468

9 Remove ring, stopper pin and pin turret side.

F7469
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10 Remove boom cylinder.

Remove boom cylinder other direction as above.

F7470
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FA6-1-27

FRONT-END ATTACHMENTS EX135W

Install boom cylinder

1 Hoist boom cylinder, then, align boom cylinder

bottom side with main frame.

F7470

2 Install pin, stopper pin and ring.

F7469

3 Install boom cylinder other direction as above.

4 Install hoses to the boom cylinder.

Tightening torque: 70 Nm

F7468

5 Hoist boom cylinders. Then align rods with boom.

21599 60406991

Start the engine.

Align the hole of boom cylinders rod end with
the hole of boom center by operating to extend
or to retract the rods.

F7464
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FA6-1-28

FRONT-END ATTACHMENTS EX135W

6 Act alternatively from one side and from the

opposite side to connect the cylinder rods to the
boom.

7 MONOBLOC BOOM VERSION

Install stopper pins and rings.

TRIPLE ARTICULATION VERSION

Mount the plate securing screws.

Tightening torque: 19 daNm.

F7465

8 Install lubricate piping to the boom cylinder.

Tightening torque: 35 Nm

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FA6-1-29

FRONT-END ATTACHMENTS EX135W

Removal of positioning cylinder

TRIPLE ARTICULATION VERSION

1 Place the unit on level ground.

F9327

2 Put wooden block under the cylinder.

F5440

3 Stop the engine, then press on top of exhaust

valve to release pressure in hydraulic tank.

F7453

4 Remove lubricate piping from rod side of positio-

ning cylinders.

F7473

5 Remove ring (1) and stopper pin (2). 4

Hoist positioning cylinder.
Push out pin (3) with bar and hammer. 1
Remove washers (4). 2
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F7474
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FA6-1-30

FRONT-END ATTACHMENTS EX135W

6 Fasten a wire to positioning cylinder to hold

cylinder rod.

F6993

7 Remove positioner hoses.

Install plugs to all side of pipings and hoses.

F7475

8 Disconnect luricate pipings from the head side

of cylinders.

F7473

9 Push out ring (5), stopper pin (6), and hinge pin
the remove the cylinder and his washer (8).

8
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8
7 5
6 F7476
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FA6-1-31

FRONT-END ATTACHMENTS EX135W

Install positioning cylinder

TRIPLE ARTICULATION VERSION

1 Install cylinder to the boom.

F7067

2 Mount the cylinder from the back side with shims

(8) in correspondence with the boom pivot point. 8
Install pin (7), stop pin (6) and ring (5).

8
7 5
6 F7476

3 Install lubricate hoses for the head side of positio-

ning cylinder.
Tightening torque: 35 Nm

F7473

4 Remove all plugs and control hoses to cylinder.

Tightening torque: 180 Nm

F7475
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5 Hoist cylinder, then align cylinder rod and his

washer (4) with positioner.

F7477
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FA6-1-32

FRONT-END ATTACHMENTS EX135W

6 Install pin (3), stopper pin (2) and ring (1).

1
2

F7474

7 Install lubricate hoses for rod sid of positioning

cylinder.
Tightening torque: 35 Nm

F7473

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FA6-1-33

FRONT-END ATTACHMENTS EX135W

SPECIFICATIONS

Boom cylinder (monobloc boom version)

Bore x Rod dia. x stroke 115 x 80 x 955 mm

Minimum retracted length 1800 mm

Boom cylinder (triple articulation version)

Bore x Rod dia. x stroke 115 x 80 x 965 mm

Minimum retracted length 1475 mm

Arm cylinder
Bore x Rod dia. x stroke 120 x 85 x 1140 mm

Minimum retracted length 1935 mm

Bucket cylinder
Bore x Rod dia. x stroke 115 x 80 x 920 mm

Minimum retracted length 1440 mm

Positioning cylinder (triple articulation version)

Bore x Rod dia. x stroke 150 x 90 x 770 mm

Minimum retracted length 1385 mm

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FA6-1-34

FRONT-END ATTACHMENTS EX135W

1.5.2 REMOVAL AND INSTALLATION OF THE FRONT-AND ATTACHMENT

Removal of front attachment assembly

1 Place the excavator on level ground.

Lower bucket to the ground.
Stop the engine.
Remove the air breezer cap, and draind the air
in the oil tank.

F7491

2 Disconnect lubrication hoses at adapters from

boom cylinder rod ends.

F7481

Adaptor

3 Remove rings, pins and stoppers of the pin Stopper

connecting with boom cylinder rod ends and Ring
boom.
Pin

F7482

4 Fasten sling to the lifting cylinders.

MONOBLOC BOOM VERSION

Push pin with bar and hammer far enough to
remove cylinder rod.

TRIPLE ARTICULATION VERSION

Remove the plate securing, then withdraw the
pin far enough to disconnect the cylinder from F7479

with a punch and hammer.

CAUTION
Be careful not to completely withdraw the pin, in order
to avoid the disconnection of boom and positioning
21599 60406991

arms.

5 Lower right boom cylinder to put it on stand.

Push pin in other direction to remove other (left)
boom cylinder.
Lower other (left) boom cylinder.

F7492
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FA6-1-35

FRONT-END ATTACHMENTS EX135W

6 Disconnect hoses of cylinders.

Nota: Note: Four pipes for the monobloc version
(bucket and dipper stick cylinders) and six for
the triple articulation version (bucket, dipper stick
and positioning arm cylinders).

Close all openings with plug to keep clean.

F7487

7 Remove ring, pin and stopper of the boom foot

pin.

Pin
Stopper
Ring
F7485

8 Fasten sling to the front end attachment.

F7480

9 Pull the boom foot pin with tool.

Remove the boom foot pin. Recover the shims
from the inner side of the base pivot point of the
main frame.

F7488

10 Remove the front end attachment.

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F7490
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FA6-1-36

FRONT-END ATTACHMENTS EX135W

Reinstall the front attachment ass'y

1 Fasten align to the front attachment ass'y.

Install dust seals to boom foot.
Align boom foot boss with the main frame boss.

F7490

2 Install boom foot pin with hummer.

Install pin and ring.

F7486

3 Remove the plugs to keep clean.

Connect the hydraulic hoses (four or six hoses,
depending upon the version).

F7487

4 Secure a cable to each cylinder and align the

rods with the boom.

F7483

5 Start engine.
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Align the holes on the rod side of the boom

cylinders with the hole at the center of the boom
itself, actuating the pilot valve in the lifting
position, to extend or retract the rods.

F7479
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FA6-1-37

FRONT-END ATTACHMENTS EX135W

6 Act alternatively from one side and from the

opposite side to connect the cylinder rods to the
boom.

F7489

Stopper
Ring
7 Install stoppers, pins and rings on both sides.
Pin

Note: In the triple articulation version, secure F7482

the block with screws directly on the surface of
the pin.

Tightening torque: 19 daNm.

8 Connect lubrication hoses with boom cylinder

rod ends.
Tightening torque: 35 Nm

F7481
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FA6-1-38

FRONT-END ATTACHMENTS EX135W

NOTES:

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OPERATIONAL PRINCIPLE CY6-2-1

(O/P)
HYDRAULIC CYLINDERS EX135W

2. HYDRAULIC CYLINDERS

2.1 CONSTRUCTION AND FUNCTION

Four double acting cylinders 1 bucket cyl., 1 arm cyl., 2 boom cyl. - are used on the hoe attachment (mobloc
version). For front tool control (triple articulation) 5 hydraulic double acting cylinders are foreseen: bucket
cylinder (1), arm cylinder (1), position cylinder (1), boom cylinder (2). All cylinders are similar operation and
construction in general.

CUSHION CYLINDER

For shock absobing of rod movement at the stroke end, cushion mechanism is provided in the top chamber
of all cylinders, and the bottom chamber of arm cylinder as shown in the following figures.

When piston aproches to the stroke end, return oil flow through the passage between cushion ring and head.

BOOM AND BUCKET CYLINDER

ARM CYLINDER
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OPERATIONAL PRINCIPLE CY6-2-2

(O/P)
HYDRAULIC CYLINDERS EX135W

NOTES:

21599 60406991
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DISASSEMBLY AND ASSEMBLY CY6-2-1

(D/A)
HYDRAULIC CYLINDER EX135W

2.1 DISASSEMBLY AND ASSEMBLY

2.1.1 DISASSEMBLY

Instructions for the disassembly of boom, arm and bucket cylinder are similar.
Note: Before disassembly, throughly clean the outside of the cylinder.

1 Fasten the cylinder assembly on the work-

bench.

F3281

2 Remove the pipes from the cylinder.

F3282

3 Fully extend rod (02) and support the weight

of the rod with a hoist. Remove eight socket
bolts (04) from head (03).

F3283

4 Tap the head out of the cylinder using a soft

hammer.
21599 60406991

F3283
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DISASSEMBLY AND ASSEMBLY CY6-2-2

(D/A)
HYDRAULIC CYLINDER EX135W

5 Pull the rod assembly (02) out of the cylinder

(01).

F3285

6 Cut off the lock points of the piston nut (20)

on the corn (21) with a drill.

F3286

7 Remove corn (21) from the piston nut (20).

Remove ball (22) from inside.

F3287

8 Fasten the rod assembly on the workbench.

To aid assembly, put marks on the rod end
and piston nut.

(Cylinder overhauling workbench, including

hydraulic wrench for cylinder unscrewing and
tightening to torque: 75297916).

F3288

9 Loosen piston nut (20) with tool.

Tool: 75298362 for boom cylinder,

bucket and arm cylinder
21599 60406991

75298684 for positioning cylinder

F3289
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DISASSEMBLY AND ASSEMBLY CY6-2-3

(D/A)
HYDRAULIC CYLINDER EX135W

10 Remove piston nut (20) and shim from rod

(19).

F3290

11 Remove piston (18) from the rod.

F3291

12 Cut seal ring (14) on the piston (18).

F3292

13 Remove the four slide rings (15) (16) from

the piston.

F3293

14 Remove the brake bushing (17) from the rod.

Note: The positioner cylinder has no brake

bushing.
21599 60406991

F3294
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DISASSEMBLY AND ASSEMBLY CY6-2-4

(D/A)
HYDRAULIC CYLINDER EX135W

15 Pull head (03) out of the rod.

F3295

16 Remove wiper (05), slide ring (06), main

gasket (08) and backup ring (07) from the
head.

F3296

17 Remove buffering assembly (09) with a pick.

F3297

18 Remove retaining ring (11).

F3298

19 Remove bushing (10) from head.

21599 60406991

F3299
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DISASSEMBLY AND ASSEMBLY CY6-2-5

(D/A)
HYDRAULIC CYLINDER EX135W

2.1.2 INSPECTION

1 Check the surfaces of piston and head for

damage or score. If repared leaks occur,
care particularly attention to score or wear
on the seal lips.

When assembling cylinder, change wearing

parts such as: wiper, oil seals, slide ring, O-
rings and backup rings.
F3300

2 Check the grooves and lands on piston and

head are clear and free from nicks or burrs.

Examine the sliding surface of bushing. If

there is any damage: change bushing.

F3301

3 Check the threads of rod and nut for da-

mage or fault. Light damage may be re-
paired using a file or a lathe.
If damaged excessively the part should be
renewed.

F3302

4 Examine bent of the rod.

Place the rod on the V-blocks and set a
gauge, rotate rod to measure bent of rod. If
bent is excessive the rod should be re-
newed.

Bent limit: 0.5 mm per 1.0 m length.

F3303

5 Check the surfaces of rod and cylinder boar

for scores, scratches and wear. If score or
wear is excessive, the part should be re-
newed.
21599 60406991

Wear limit: see page 13.

F3304
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DISASSEMBLY AND ASSEMBLY CY6-2-6

(D/A)
HYDRAULIC CYLINDER EX135W

2.3.1 ASSEMBLY

Instruction for the disassembly of boom, arm and bucket cylinder are similar.
Note: 1) Before assembly, clean all internal parts using clean hydraulic oil and dry by air.
2) No foreign material shall remain inside the cylinder.
3) Check possible damages on the surface. Remove by abrasion.
4) We recommend to change all gaskets.

1 Install gasket (14) on piston (18) with tools

kit. tool:

75298983 for boom cylinder and

bucket
75299005 for arm cylinder
75299006 for positioning cylinder
F3305

2 Install slide rings (15) (16).

Stagger ring gaps on the

piston as shown in the
figure.

F3306

3 Put hydraulic oil on outside of piston. Press

the piston into "correction guide" (compo-
nent of tools kit shown at point No.1) to sh-
rink the seals to the original size.

F3307

4 Press bushing (10) in hole of head (03) with

tool and install retaining ring (11).
21599 60406991

Tool: 75298693 for arm cylinder

75298673 for bucket and boom
cylinder
75298695 for positioning cylinder
F3308
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DISASSEMBLY AND ASSEMBLY CY6-2-7

(D/A)
HYDRAULIC CYLINDER EX135W

5 Install the buffering assembly (09) with the

lip toward cylinder inside.
SECONDARY JOINT ASS’Y

LIP

F3309

6 Install the O-ring (08) and backup ring (07)

with the lip toward cylinder inside.

F3310

7 Install the slide ring (06).

F3311

8 Install wiper (05) with the lip toward the

cylinder outside.
Use press and tool.
Tool: 75298699 for arm cylinder
75298670 for bucket and boom
cylinder
75298701 for positioning cylinder F3312

9 Install backup ring (12) and O-ring (13).

Put hydraulic oil on the O-ring and the seals

in head.
21599 60406991

F3313
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DISASSEMBLY AND ASSEMBLY CY6-2-8

(D/A)
HYDRAULIC CYLINDER EX135W

10 Place the rod (02) on the workbench.

Install tool on the rod with taper end toward
the thread.
Install head (03) onto the rod.
Tool: 75298696 for arm cylinder
75298676 for bucket and boom
cylinder
F3314
75298698 for bucket cylinder

11 Install brake bushing (17) onto the rod with

the taper end toward cylinder inside.
Note: the positioner cylinder has no brake
bushing.
Insert piston (18) onto the rod.

F3315

12 Install the shim (19) and piston nut (20) on

to the rod.

F3316

13 Tighten the nut with the tool (workbench

75297916).
Tool: 75298362 for boom cylinder,
bucket and arm cylinder
75298684 for positioning cylinder
Tightening torque:
374 daNm - for boom cylinder F3289
609 daNm - for arm cylinder
449 daNm - for bucket cylinder
781 daNm - for positioning cylinder

14 Install the ball (22).

21599 60406991

F3317
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DISASSEMBLY AND ASSEMBLY CY6-2-9

(D/A)
HYDRAULIC CYLINDER EX135W

15 Lock the corn (21).

If the hole on rod is not aligned with the th-

readed hole, drill a hole (ø 10 mm) on the
rod, and clean completely. Then insert the
ball and lock the corn.

Tightening torque: 5.69 daNm F3318

16 Lock the threaded hole on three points with

a hammer and a punch.

F3319

17 Hoist rod assembly (02) and keep it horizon-

tally.

Put hydraulic oil on piston (20) and bore of

cylinder.

F3320

18 Enter the piston (20) into cylinder (01) ali-

gning rod center with bore center.

Be carefull not to damage the piston seals.

F3321

19 Install head (03) with eight socket bolts

(04).

31,1 daNm - for boom and bucket cyl.s.

21599 60406991

44,2 daNm - for arm cyl.

76,4 daNm - for positioning cyl.

F3322
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DISASSEMBLY AND ASSEMBLY CY6-2-10

(D/A)
HYDRAULIC CYLINDER EX135W

20 Fully retract the rod into the cylinder.

Install the pipes on the cylinder.

F3323

2.1.4 SPECIAL TOOLS

A - PISTON NUT LOOSENING/TIGHTENING

A
75298362 for boom, bucket and arm cy-
linder
75298684 for positioning cylinder
Use cylinder overhauling workbench:
75297916

B, C, D, E - GASKET INSTALLATION AND

ADJUSTMENT

75298983 for boom and bucket cylinder

75299005 for arm cylinder
75299006 for positioning cylinder

F3324

E - GASKET ADJUSTMENT
21599 60406991

F3325
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DISASSEMBLY AND ASSEMBLY CY6-2-11

(D/A)
HYDRAULIC CYLINDER EX135W

F - WIPER INSTALLATION
75298699 for arm cylinder
75298670 for bucket and boom cylinder
75298701 for positioning cylinder

F3326

G - BUSHING INSTALLATION
75298693 for arm cylinder
75298673 for bucket and boom cylinder
75298695 for positioning cylinder

H - HEAD INSTALLATION F3327

75298696 for arm cylinder

75298676 for bucket and boom cylinder
75298698 for positioning cylinder
21599 60406991
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DISASSEMBLY AND ASSEMBLY CY6-2-12

(D/A)
HYDRAULIC CYLINDER EX135W

DETAIL A DETAIL B

N.B. THE POSITIONER CYLINDER HAS NO BRAKE BUSHING

Item Part name Q’ty Item Part name Q’ty

01 Cylinder 1 13 O-Ring 1
02 Rod 1 14 Seal ring ass’y 1
03 Head 1 15 Slide ring 2
04 Socket bolt 8 16 Slide ring 2
05 Wiper ring 1 17 Cushion ring 1
06 Slide ring 1 18 Piston 1
07 Backup ring 1 19 Shim 1
08 U-ring 1 20 Piston nut 1
09 Buffering ass’y 1 21 Set screw 1
10 Bushing 1 22 Steel ball 1
11 Retaining ring 1
12 Backup ring 1
21599 60406991
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DISASSEMBLY AND ASSEMBLY CY6-2-13

(D/A)
HYDRAULIC CYLINDER EX135W

STANDARD MAINTENANCE ROD

ND: NOMINAL DIMENSIONS

LU: LIMIT OF USE

Unit: mm

Cylinders ND (A) LU Remedy

Boom 75

Arm 80 - 0.023 REPLACE

OR PLATE
Bucket 65 WITH CHROMIUM

Positioning 90 - 0,027
21599 60406991
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DISASSEMBLY AND ASSEMBLY CY6-2-14

(D/A)
HYDRAULIC CYLINDER EX135W

NOTES:

21599 60406991
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FRONT-END ATTACHMENTS FA-6-3-1

PINS AND BUSHING EX135W
3. PINS AND BUSHINGS
3.1 SPECIFICATIONS

3.1.1 PINS AND BUSHINGS

Unit: mm
Pin Bushing
Mark Measuring part Remedy
ND LU ND LU
A Boom foot 65 64 65 66.5

B Boom cylinder 65 64 65 66.5

bottom side

Boom cylinder
C 65 64 65 66.5
rod side

D Boom top 65 64 65 66.5

Arm cylinder
E 65 64 65 66.5
rod side
Arm cylinder
F 65 64 65 66.5
bottom side
Bucket cylinder
G 60 59 60 61.5 Replace
bottom side
H Bucket cylinder
65 64 65 66.5
rod side
I Link “B” arm side 65 64 65 66.5
J Link “A” bucket side 65 64 65 66.5
Bucket
K 65 64 65 66.5
arm side
Positioner cylinder
21599 60406991

L 80 79 80 81.5
bottom side
Positioner cylinder
M 80 79 80 81.5
rod side

ND: Nominal Dimension LU: Limit of Use

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FRONT-END ATTACHMENTS FA-6-3-2

PINS AND BUSHING EX135W

3.1.2 CLEARANCE BETWEEN PINS AND BUSHINGS

Unit: mm
Clearance between Pin and Bushing
Mark Measuring part Remedy
ND LU
A Boom foot 0.35 to 0.544 2.5
Boom cylinder
B 0.15 to 0.424 2.5
bottom side
Boom cylinder
C 0.15 to 0.424 2.5
rod side
D Boom top 0.35 to 0.544 2.5

Arm cylinder
E 0.15 to 0.424 2.5
rod side
Arm cylinder
F 0.15 to 0.424 2.5
bottom side
Bucket cylinder
G 0.15 to 0.424 2.5 Replace
bottom side
Bucket cylinder
H 0.35 to 0.544 2.5
rod side
I Link “B” arm side 0.35 to 0.544 2.5
J Link “A” bucket side 0.35 to 0.544 2.5
Bucket
K 0.35 to 0.544 2.5
arm side
Positioner cylinder
L 0.35 to 0.52 2.5
bottom side
21599 60406991

Positioner cylinder
M 0.35 to 0.52 2.5
rod side

ND: Nominal Dimension LU: Limit of Use

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INDEX EX135W - 7 - 1

SECTION 7 HYDRAULIC SYSTEM

INDEX

Group 1 - GENERALITIES............................................................................................ HS7-1-1

Group 2 - MAIN HYDRAULIC SYSTEM ....................................................................... HS7-2-1

2.1 Generalities
2.2 Suction circuit and delivery circuit
2.3 Return circuit
2.4 Drainage circuit

Group 3 - PILOT/BRAKES SYSTEM ............................................................................ HS7-3-1

3.1 Generalities
3.2 Suction delivery and return circuit

Group 4 - STEERING SYSTEM .................................................................................... HS7-4-1

4.1 Generalities
4.2 Suction delivery and return circuit

Group 5 - BRAKES SYSTEM ....................................................................................... HS7-5-1

5.1 Generalities
5.2 Description of brakes system
5.3 Operation of brake pedal valve

Group 6 - OPERATION OF CIRCUITS .......................................................................... HS7-6-1

6.1 Generalities
6.2 Circuit with controls in neutral
6.3 Boom circuit
6.4 Dipper stick circuit
6.5 Bucket circuit
60406991

6.6 Positioner arm circuit

6.7 Travel circuit
6.8 Blade (small dozer) blade control
21599

6.9 Side stabilisers control circuit

6.10 Turret swing circuit
6.11 Hydraulic oil heating circuit

(continued)
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INDEX EX135W - 7 - 2
INDEX (continued)

Group 7 - TRAVEL CIRCUIT ........................................................................................ HS7-7-1

7.1 Description
7.2 Travel hydraulic motor control circuit
7.3 Transmission control circuit
7.4 Parking brake control circuit

Group 8 - HYDRAULIC SYSTEM DIAGRAM .................................................................. HS7-8

60406991
21599
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HS7-1-1

HYDRAULIC SYSTEM EX135W

1. GENERALITIES

The hydraulic system includes the MAIN HYDRAULIC CIRCUIT, the PILOT AND BRAKES CIRCUIT and the
HYDRAULIC STEERING CIRCUIT.

The main hydraulic circuit is used to send hydraulic power to the actuators and the motors.

The pilot and brakes circuit is used to control all the functions of the control valve, thus driving the actuators
and the motors.
Moreover, the pilot and brakes hydraulic circuit actuates the brake pistons on the front and rear axle, through
the brake pedal control.

The steering hydraulic circuit is used to control the steering system through the power steering valve actuated
by the steering column.

The hydraulic system includes a main pump and a secondary pump, both of a variable displacement type,
engine driven through an elastic coupling, and a gear double fixed displacement pump for the pilot, brakes
and steering system, driven by the engine timing drive.
The hydraulic oil delivered by the main pump flows through the body of control valve (M7) to the dipper stick
cylinder, the boom cylinders, the bucket cylinder and eventual positioner, and the travel motor.
The hydraulic oil delivered by the secondary pump flows, through the body of control valve (M8) to the turret
swing motor and the blade and/or side stabilisers control.
The hydraulic oil delivered by the pilot and brakes pump, after going through an oil filter, feeds the brakes
system valve, then, through the priority valve, feeds, with a constant flow line, the service solenoid valves
group that in turn feed the pilot valves, the pedals and then the control valve, and the transmission shift and
parking brake valves.
The secondary pilot line feeds the rotation circuit of the clam bucket.
The hydraulic oil delivered by the steering pump feeds the power steering valve, that through the movement
of the steering columns, drives the steering cylinder.
60406991
21599
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HS7-1-2

HYDRAULIC SYSTEM EX135W

NOTES:

60406991
21599
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HS7-2-1

MAIN HYDRAULIC SYSTEM EX135W

2. MAIN HYDRAULIC SYSTEM

2.1 GENERALITIES

The main hydraulic system includes a suction circuit, a delivery circuit, a return circuit and a drainage circuit.

The main system includes a main hydraulic pump (type A11V0) and a secondary pump (type A10V0).

The main pump (A11V0) feeds, through the right body of the control valve (type M7) the travel motor, the dipper
stick cylinder, the two boom cylinders, the positioner cylinder and the bucket cylinder.
The secondary pump (A10V0) feeds, through the left body of the control valve (type M8) the turret swing motor
and the blade/side stabiliser control.

The main and secondary pumps are of a variable displacement, axial pistons type and are tandem mounted
and connected to the engine by an elastic coupling.
The hydraulic oil delivered by the main and secondary pumps flows to the control valve controlling the various
hydraulic functions, regulating the delivery to the various actuators (cylinders and motors); the hydraulic oil
returning from the actuators, through the control valve, is sent to the oil radiator, where it is cooled and then
returned to the hydraulic reservoir through a total flow filter.
60406991
21599
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HS7-2-2

MAIN HYDRAULIC SYSTEM EX135W

2.2 SUCTION CIRCUIT AND DELIVERY CIRCUIT

The main pump (A11V0) sucks the hydraulic oil from the hydraulic reservoir through a suction filter located
on the line inside the hydraulic reservoir.
The delivery of the main pump reaches the body of control valve (M7) at port P1 whereas the delivery of the
secondary pump reaches the body of control valve (M8) at port P2.

1. Reservoir
2. Suction filter
3. Secondary pump (A10VO)
4. Main pump (A11VO)
5. To engine
6. Control valve
7. Right body (M7) 6
8. Left body (M8) T
9. To oil radiator M8 M7 7
8

1 P2 K P1

3 4

2
5
60406991
21599
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HS7-2-3

MAIN HYDRAULIC SYSTEM EX135W

5 7
6

P1
K
8
P2

1
2
3

F3812

1. Reservoir
2. Suction filter
3. Secondary pump
60406991

4. Main pump
5. Control valve
6. Left body (M8)
21599

7. Right body (M7)

8. To oil radiator
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HS7-2-4

MAIN HYDRAULIC SYSTEM EX135W

2.2.1 DELIVERY PRESSURE CONTROL

The control of the maximum pressure of the main hydraulic system of the main pump is provided by two valves
mounted on the right block (M7).
a) The pressure cutting relief valve set at 280 bar, limits the line pressure by working on the pilot signal of
pump (LS). The pump provides only the quantity of oil required by the actuators.
b) The max. pressure relief valve set at 320 bar, limits the line pressure discharging the oil flow delivered by
the pump.
This valve works only in case the pressure cutting relief valve (a) fails to operate.

The max. pressure regulation of the main hydraulic circuit of the secondary pump (swing/services) is provided
by a max. pressure relief valve set at 330 bar mounted on the left block of control valve (M8), operating in case
the pressure regulator (cut-off valve) mounted on the pump, set at 310 bar, fails to work.

2.2.2 SECONDARY PUMP DELIVERY REGULATION

When control valve (M8) (left body with open center operation) has the spools in neutral position, and the motor
is rotating (see fig. 2), the pump works in max. displacement condition and the fluid reaches the open center
circuit of the left side of the control valve (M8), goes through the control valve (swing and blade/stabilisers
spools in neutral) and, passed the 5.5 bar check valve, reaches the oil radiator, is cooled and returns to the
reservoir.
Under low temperature conditions (high oil viscosity) or clogging of the oil cooler, the return pressure exceeds
7.1 bar, actuating the by-pass valve allowing the hydraulic oil to flow directly toward the reservoir, thus avoiding
the radiator.
Under these conditions, the spring on the counter piston prevails over the swashplate, keeping the pump in
max. displacement.

The chamber of the pump swashplate control cylinder is connected to the reservoir through pipe L. Under
working conditions (control valve spools moved from neutral position) on actuators requiring a pressure below
the beginning of regulation (a, fig. 1), the regulation occurs by a choking of the pilot valve. The control of the
delivery is only obtained by the movement of the control valve spool regulating the flow, thus changing the
speed of the movement.
If the load of the actuator requires a pressure higher than Pa, (fig. 1) the power regulation valve (4) intervenes,
with the consequent reduction of the speed of the actuator.
Beyond point (a), the power regulation valve (4) presses the setting valve; the pilot line generates a pressure
drop on the 0.8 mm restriction and the displacement regulation valve (1), in absence of the piloting pressure
in addition to the pre-load of the spring, moves to the right (see fig. 3) opening the duct to the swashplate control
piston (3) that with its movement reduces the displacement of the pump and changes the setting of power
regulation valve (4) until a new equilibrium point is found.
If the load of the actuator continues to change, the displacement regulation valve (1) continues to modulate
searching for a point of equilibrium.
When a 310 bar pressure is reached on the operating line, the cut-off valve intervenes (see fig.4).

When the spool of the cut-off valve moves, the displacement regulation valve (1) is intercepted and any further
load increase has no effect on the regulation, but the secondary pump will take an angle ensuring that the
pressure in the line is maintained compensating also eventual leakages in the circuit. Thus, the intervention
of the cut-off circuit limits the max. delivery pressure at 310 bar.
The secondary pump sends, during its operation, a Cross Sensing signal proportional with the load applied
60406991

to the secondary pump.

This signal generated by the secondary pump is sent to inlet Z of the main pump and allows the regulation
of the displacement of the main pump as a function of the load on the secondary pump, giving priority to the
21599

latter in case of combined operation.

This Cross Sensing device has the purpose of avoiding, in case of combined operations, that the addition of
the powers required by the actuators does not exceed the power that can be provided by the engine.
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HS7-2-5

MAIN HYDRAULIC SYSTEM EX135W

P2

P B
X

Ø 0.8

b
Pressione
Pressure

(1)

CUT-OFF: 310 bar

Pa a (2)

Q
0 Portata
Delivery (4) (3)

Fig. 1 Secondary pump P - Q curve

a) beginning of regulation intervention
b) cut-off intervention
(5)

Q max Q min.
S L1 L
CROSS SENSING

(1) Delivery regulation valve

(2) CUT-OFF valve (DR) Fig. 2 Operation of secondary pump
(3) Swashplate control piston under minimum load condition
(4) Power controlling valve
(5) Counter piston

P2 P2

B B
X X
Ø 0.8 Ø 0.8

(1) (1)

CUT-OFF: 310 bar CUT-OFF: 310 bar

(2) (2)

(4)

(4) (3) (3)

60406991

(5) (5)
21599

Q max Q min. Q max Q min.

CROSS SENSING
S L1 L CROSS SENSING
S L1 L

Fig. 3 Operation of secondary pump with Fig. 4 Operation of secondary pump

intervention of regulator with CUT-OFF intervention
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HS7-2-6

MAIN HYDRAULIC SYSTEM EX135W

2.2.3 REGULATION OF MAIN PUMP DISPLACEMENT

With the spools of the right control valve body (M7) (operation at closed center) in neutral position (see fig.6),
without a load demand, the pump is positioned with the swashplate on minimum displacement. This occurs
when the pilot pressure derived from the delivery line, is sent to Load Sensing valve (1), that, overcoming the
load of the spring, moves the plunger of valve LS (1), connecting the pilot line with the swashplate control
piston (5). Under these conditions, the pump is positioned at minimum displacement.

If by intervening on a pilot valve the operator moves a spool, the main line opens and a pressure drop occurs,
operating the Load Sensing valve (1) moved by the spring.
This intercepts the swashplate control piston operating line and the pump will tend to move toward max.
displacement.
The equilibrium point is reached when between line P1 and line LS a pressure differential DP of 20 bar is
established.
With reference to figure 5, the pump displacement regulation between point 0 and point a, is controlled by the
operator (in practice, the whole delivery of the pump reaches the actuators) and the equilibrium position of
the pump swashplate is obtained when the pressure differential DP between line P1 and LS generated when
the hydraulic oil flow passes through the control valve spools equals 20 bar. The operating speed of the
actuators between point 0 and point a is controlled by the operator and is proportional to the movement of the
pilot valve.
If point a is exceeded, the operating speed of the actuators will be a function of the load power required only
and not of the position of the pilot valve.
From point a to point b of the curve, the pump displacement will be reduced as a function of the power required
by the load through the operation of the power regulation valve (2).

Under regulating conditions, if another actuator fed by the secondary pump is actuated at the same time, the
pump, as soon as the regulator intervenes, it sends a Cross Sensing signal (monitoring the load applied) to
the main pump (inlet Z) in addition to the movement of the displacement regulation valve.
The intervention of the Cross Sensing valve on the main pump applied to the swashplate control piston (5)
changes the angle of the pump swashplate toward maximum displacement (see fig. 8).

Consequently, the effect of a load applied to the secondary pump is reflected also on the main pump.
In practice, to each load increase on the secondary pump, the displacement of the main pump is reduced
accordingly, so that the load on the engine stays even.

60406991
19400
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HS7-2-7

MAIN HYDRAULIC SYSTEM EX135W

P LS

P1

M G R T2 Z
B T1 X
b
Pressure
Pressione

c (6) (1)
a

(2)
0 (3)
Q
Delivery
Portata

<
MOTORE
DIESEL (4)

<
Fig. 5 Main pump P - Q curve DIESEL
ENGINE Q max Q min.
a) beginning of regulation intervention
b) beginning of pressure cut relief val-
(5)
ve (on control valve)
c) reduction of displacement of main
pump caused by Cross Sensing
S M1

Fig. 6 Operation of main pump under

no load conditions
(1) Load Sensing valve
(2) Power regulation valve
(3) Cross Sensing valve
(4) Counter piston
(5) Swashplate control piston
(6) Piloting pressure

LS LS

P1 P1

M G R T2 X Z
M G R T2
B T1 B T1 X Z

∆ P= 20
∆ P= 20

(6) (1) (6) (1)

(2) (2)
(3) (3)
<

<

DIESEL
MOTORE (4) MOTORE
DIESEL (4)
<

<

DIESEL
ENGINE DIESEL
ENGINE
Q max Q min. Q max Q min.
60406991

(5)
(5)
19400

S M1 S M1
F11056
F11057

Fig. 7 Operation of main pump under condition of Fig. 8 Operation of main pump under load
power regulation intervention condition and intervention of cross
sensing
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HS7-2-8

MAIN HYDRAULIC SYSTEM EX135W

2.3 RETURN CIRCUIT

The oil of the actuators operated by the main pump through the control valve right body and the oil of the
actuators operated by the secondary pump through the control valve left body, reach the hydraulic reservoir
through a return circuit equipped with two pressure relief valves with different settings, located inside the
control valve.

The pressure setting of the pressurisation and check valve (9) is 5.5 bar, whereas the safety and by-pass valve
(thermostat function) is set at 7.1 bar.

Once the operating temperature is reached, the oil returns to the hydraulic reservoir, through the pressurisation
and check valve (9) and the oil radiator, where it is adequately cooled.

When the oil temperature is low, the relative viscosity increases, with a subsequent higher resistance to the
flow through the radiator. If the oil pressure exceeds 7.1 bar, both for high oil viscosity (thermostatic valve
function) and the eventual clogging of the radiator, the oil returns directly to the reservoir, by-passing the
radiator.

The hydraulic reservoir contains a total flow oil filter, capturing eventual dirt in the return oil coming from the
actuators.

10 10

9 K
5.5 bar
7 8

7.1 bar
T
5
6
2

1 - Hydraulic reservoir
2 - Oil radiator
3 - Total flow filter
4 - By-pass valve 4
5 - Radiator safety and by-pass
valve
1.5 bar
6 - Control valve central body
60406991

7 - Control valve left body

8 - Control valve right body 3
21599

9 - Pressurisation and check

valve
10 - Actuators
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HS7-2-9

MAIN HYDRAULIC SYSTEM EX135W

2
5
T
7
1
K

6
10
8

F3813

1 - Radiator by-pass valve (7.1 bar)

2 - Total flow filter
60406991

3 - By-pass valve closed

4 - Control valve
5 - Oil reservoir
21599

6 - Radiator oil inlet

7 - Pressurisation and check valve
(5.5 bar)
8 - Radiator oil outlet
9 - By-pass valve open
10 - Oil cooler
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HS7-2-10

MAIN HYDRAULIC SYSTEM EX135W

2.4 DRAINAGE CIRCUIT

Since internal leakages of hydraulic oil occur in the hydraulic motors and hydraulic oil is used as lubricant, an
oil drainage circuit is mounted sending the hydraulic oil to the reservoir.

Travel motor drainage circuit

The oil leaking from the travel motor flows out the drainage through a pipe and the center joint, and returns
to the hydraulic reservoir.

Swing motor drainage circuit

The drainage oil of the swing motor, returns to the hydraulic reservoir through a hose.

Pumps drainage circuit

Both main pump than the secondary pump have a drainage pump connected directly with the hydraulic
reservoir.

4 1 3
T1

6
L
5

1 - Travel motor
2 - Hydraulic reservoir
3 - Swing motor
4 - Main pump
60406991

5 - Secondary pump
6 - Center joint
21599
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HS7-2-11

MAIN HYDRAULIC SYSTEM EX135W

F7686

5 4
60406991

1 - Travel motor
2 - Hydraulic reservoir
21599

3 - Swing motor
4 - Main pump
5 - Secondary pump
6 - Center joint
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HS7-2-12

MAIN HYDRAULIC SYSTEM EX135W

NOTES:

60406991
21599
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HS7-3-1

PILOT/BRAKES SYSTEM EX135W

3. PILOT/BRAKES SYSTEM

3.1 GENERALITIES

The pilot/brakes hydraulic circuit includes a gear pump, a priority valve, a pressure relief valve set at 35 bar,
a service solenoid valve group allowing the feeding to the pilot valves, pedal and various circuits.

The hydraulic oil of the piloting system feeds the following circuits:

a) The front and rear axle brakes system through a brakes valve.

b) The manual valves and pedal actuating the various control valve spools.

c) The transmission shift system.

d) The rotary bucket control (optional).

e) Through the services solenoid valve group, to operate the axle lock, the blade and/or side stabiliser
valve, the travel transmission high/low speed shift, the left/right stabilisers selector and the hammer
control valve (optional).

3.2 SUCTION DELIVERY AND RETURN CIRCUIT

The pilot/brakes pump sucks the oil through a suction filter from the hydraulic reservoir and sends it, after
passing through the delivery filter, to the brakes valve and then, after charging the brake system accumulators,
to the priority valve feeding the controls.

The priority valve ensures a constant delivery at 12 liter/min to the services solenoid valve group feeding line.
After passing the priority valve, the pilot system oil reaches, through a diversion, the transmission shift valve
and the relevant accumulator. Through another diversion, the pilot oil pressure, after passing the check valve,
charges the pilot system accumulator and feeds, through a max. pressure relief and safety valve set at 35 ±
3 bar, a series of 7 service solenoid valves.
A diversion from the priority valve (secondary line) feeds solenoid valve C1 controlling the clam bucket.
60406991
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HS7-3-2

PILOT/BRAKES SYSTEM EX135W

3.2.1 PILOT/BRAKES HYDRAULIC SYSTEM BLOCK TYPE DIAGRAM

1 Hydraulic reservoir
2 Pilot system and brakes pump
3 Pilot system filter
4 Brake valve
5 To front axle brake
6 To rear axle brake
7 Brake system accumulators
8 Priority valve
12 Pilot system accumulator
13 Services solenoid valve group
15 Transmission accumulator
16 Transmission shift solenoid valve group
17 Diverter block
18 Parking brake solenoid valve A0
19 Control check solenoid valve A1
20 Axle lock solenoid valve A2
21 Travel / blade speed range solenoid valve A3
22 Left/right side stabiliser control solenoid valve A4
23 Hammer valve control solenoid valve A5
24 Axle lock valve
25 Blade/stabiliser selector valve
26 Left/right stabilisers selector valve
27 Hammer control valve
28 Travel/positioner arm selector valve
29 Pedal pilot valve
30 Bucket/boom pilot valve
31 Arm/swing pilot valve
32 Dipper stick/blade/stabiliser selector solenoid valve
33 Control valve
34 To clam bucket solenoid valve
35 To clutch control
36 To speed shift selector control
37 To parking brake control
38 Check valve
39 Pilot valve pressure relief valve
40 Travel motor
60406991

41 Graf-cutter control solenoid valve A6

21599
 21599 60406991

50 bar
S
7 7 7

R R R

T1
5
T PD P
1 2 3 4
T2
6

1 (P)

15 2 (B)
8 34 40 25
1 8 bar
35
2 3 (A)
36 16
3
37
38 24
13 bar 26 27
12

13
18 19 20 21 22 23 41
(A1) (A2) (A3) (A4) (A5) (A6)
(A0)

39
PILOT/BRAKES SYSTEM EX135W

P5

P P4
17

28 29 P1
P P

30 31 32

33
F7185
HS7-3-3
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HS7-3-4

PILOT/BRAKES SYSTEM EX135W

3.2.2 SERVICES SOLENOID VALVES GROUP

The services solenoid valves group, mounted on a single block, feed the following systems:

- Solenoid valve A0, Two way, two positions solenoid valve, normally closed. It
parking brake feeds the pedal controlling the travel and positioning arm
depending upon the rest or energised condition of solenoid
valves B3 and B4.
This solenoid valve is energised by the parking brake button
switch and in these conditions it cuts off the possibility of
controlling the travel function.

- Solenoid valve A1 Three way, two position solenoid valve, normally closed.
control check It feeds, through a diverter block (17), the single lever pilot
valve controlling boom, bucket, swing, dipper stick and
blade and/or side stabilisers, depending upon the rest/
energised state of solenoid valves B1 and B2.
When the electric circuit is ON by the starter key, the
solenoid valve is positioned open and maintains this condition
as long as the electrical circuit is not cut-off. The electric
circuit can be voluntarily cut-off by lifting the arm rest
carrying the left pilot valve with the switch mounted at its
end, or by actuating the appropriate safety switch for road
travel, located on the dashboard.

- Solenoid valve A2 Three way, two position solenoid valve, normally closed.
axle lock When energised, it moves to open position and allows the
oil of the system to pilot the front axle lock valve. In rest
conditions, it cuts the hydraulic circuit and, consequently,
the axle lock valve, normally closed, intercepts the hydraulic
connection between the two lock cylinders.

- Solenoid valve A3
travel / blade speed range
Three way, two position solenoid valve, normally closed.
When energised, it sends the piloting oil to the regulator of
the travel hydraulic motor, to keep it in max. displacement
(slow travel speed = turtle).
When the solenoid valve is in rest position, the regulator is
connected to the reservoir (normal speed = rabbit).
The same solenoid valve allows the operation of the blade/
side stabilisers.

- Solenoid valve A4 Three way, two position solenoid valve, normally closed.
Left/right side stabiliser control When actuated, it sends pilot oil to the left/right side stabilisers
selector valve.
60406991

- Solenoid valve A5
21599

Three way, two position solenoid valve, normally closed.

hammer valve control When actuated, it sends pilot oil to the hammer valve.

- Solenoid valve A6 Three way, two position solenoid valve, normally closed.
graf-cutter control When actuated, it sends pilot oil to the graf-cutter .
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HS7-3-5

PILOT/BRAKES SYSTEM EX135W

3.2.3 PILOT SYSTEM ACCUMULATOR

The membrane type accumulator for the pilot system has the purpose of allowing a certain quantity of
actuations with engine inoperative. The membrane accumulator is made of a pressure resistant steel
container, having, inside, a membrane made of elastic material as separation element. The membrane
is locked by a ring nut between the lower and higher side of the body. In the central lower part of the membrane,
a metallic disc is incorporated, to prevent its exit through the fluid inlet port. The accumulator is filled, from
its upper part, by a nitrogen pre-load at 13 bar, whereas the lower part is connected to the pilot hydraulic
system, after a check valve. Without hydraulic pressure, the membrane, loaded on the gas side at the pre-
load pressure, is leaning against the inner surface of the accumulator and the mushroom closing the fluid
passage.
When piloting hydraulic pressure is applied, once it exceeds the pre-load pressure, the mushroom is lifted and
hydraulic oil enters the accumulator, pressurising the nitrogen.
The useful quantity of oil results from the difference between the gas volume and the minimum and maximum
operating pressure.

1 - Gas valve
2 - Container
3 - Membrane
4 - Valve mushroom
5 - Oil side connection
60406991
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HS7-3-6

PILOT/BRAKES SYSTEM EX135W

3.2.4 PILOT/BRAKES SYSTEM

1 Diesel engine
2 Pilot system and brakes pump
3 Steering pump
4 Pilot system filter
5 Brake valve
6 Brake low load pressure switch
7 Brake system accumulators
8 Priority valve
9 To front axle brake
10 To rear axle brake
11 Stop lights pressure switch
12 Pilot system accumulator
13 Services solenoid valves group
14 Center joint
15 Transmission accumulator
16 Transmission shift control solenoid valves group
17 Pilot block
18 Solenoid valve A0, parking brake and travel cut-off control
19 Solenoid valve A1, pilot system cut-off control
20 Solenoid valve A2, axle lock
21 Solenoid valve A3, travel speed shift
22 Solenoid valve A4, left/right side stabilisers (optional) control
23 Solenoid valve A5, hammer valve control
24 To axle lock valve
25 To blade/stabiliser selector valve and travel motor “X” connection
26 To left/right stabilisers selector valve
27 To hammer valve
28 Solenoid valve, travel/positioner arm selection
29 Pedal pilot valve, travel/positioner arm
30 Pilot valve, bucket/boom
31 Pilot valve, dipper stick/swing
32 Solenoid valve, dipper stick/blade/stabilisers selection
33 From hydraulic reservoir
34 To clam bucket control solenoid valve (optional)
35 To clutch control
36 To speed shift control
60406991

37 To parking brake
38 To check valve grass-cutter/hammer (optional)
21599

39 Pilot system pressure relief valve

40 Control valve
41 Graf-cutter contorl solenoid valve A6
42 Block
43 To grass-cutter spool
57 Brake accumulator charge pressure sensor
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HS7-3-7

PILOT/BRAKES SYSTEM EX135W

F11058
57
43
60406991
19400
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HS7-3-8

PILOT/BRAKES SYSTEM EX135W

NOTES:

60406991
21599
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HS7-4-1

STEERING SYSTEM EX135W

4. STEERING SYSTEM

4.1 GENERALITIES

The steering hydraulic system includes a gear type pump, a power steering valve and a steering cylinder.

The hydraulic oil flows from the steering pump to the power steering valve where, after the pressure regulation,
through the center joint, reaches the steering control cylinder.
The oil will actuate on the right or left side of the steering piston, depending upon the rotation direction given
to the steering wheel.

STEERING SYSTEM BLOCK TYPE DIAGRAM

13

6
11

P
1 4 7 8 9 10 12

5
2
11
3
T

14
60406991

1 - Oil reservoir 8 - Safety and pressure relief valve

2 - Suction filter 9 - Power steering control valve
21599

3 - Suction 10 - Anticavitation valve

4 - Steering pump 11 - Shockless valve
5 - Delivery 12 - Steering cylinder
6 - Steering valve assembly 13 - Steering wheel
7 - Check valve 14 - Return
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HS7-4-2

STEERING SYSTEM EX135W

4.2 SUCTION DELIVERY AND RETURN CIRCUIT

The steering pump sucks the oil through the suction filter from the hydraulic reservoir and sends it directly to
inlet P of the power steering valve.
The pressure of the hydraulic oil, at the inlet of the power steering valve, is regulated by a pressure relief valve
set at 140 +5 bar,
-0
then, through a check valve, reaches the power steering control valve, driven by the steering
wheel.
With the steering wheel standing still, the power steering control valve is in neutral position and the piloting
oil can flow to the return (passage from inlet P through T). Under these conditions, in case of shocks on the
wheels, the latter are absorbed by the shockless valves (set at 200 +20 bar) and are not transferred to the
-0
steering wheel. Moreover, two anticavitation valves avoid that cavitation phenomena are created in the
steering cylinder chambers.
When turning the steering wheel, the movement is transferred to the control valve, that opens gradually the
ducts to the cylinder lines, while the neutral ducts are closed.
As a consequence of the turning of the steering wheel, thus when moving the control valve, the passage of
a volume of oil occurs, directly proportionate between the angle movement of the steering wheel and the
displacement of the steering cylinder that, with its stroke, the angular movement of the steering wheels is
produced.
A follow-up system ensures that the ducts are closed when the movement of the control valve coincides with
that of the steering wheel.
The oil present in the non pressurised chamber of the steering cylinder is controlled by the same control valve
that is connected with discharge T thus, with the reservoir and, at the same time, with the pressurised oil.

60406991
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 21599 60406991

10

3
1 R

7 T

9 200 +20 bar

-0
140 +5 bar
4
at 1 l/min. -0
at 5 l/min.
8
7 P

2 L 5
6
STEERING SYSTEM EX135W

1 - Hydraulic oil reservoir

2 - Steering pump
3 - Power steering assembly 2
4 - Safety and pressure relief valve
5 - Check valve 1
6 - Power steering control valve
7 - Anticavitation valve
8 - Shockless valve
9 - Central joint
10 - Steering cylinder
F7498
HS7-4-3
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HS7-4-4

STEERING SYSTEM EX135W

NOTES:

60406991
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HS7-5-1

BRAKES SYSTEM EX135W

5. BRAKES SYSTEM

5.1 GENERALITIES

The brakes system (please refer to the figure of page 2) is made of a brake group 9, three accumulators (11)
two pressure switches (10) (12), pressure sensor (14), brake pistons on the front (1) and rear (2) axles.

5.2 DESCRIPTION OF BRAKES SYSTEM

The pilot system and brakes pump (5) driven by the diesel engine, sends the hydraulic oil through the pilot
system filter (8) to brake pedal group (9) integrated by 3 accumulators (11).
By pushing the pedal in the cab, that is an integral part of the brake group, the oil trapped by the accumulators
is gradually sent to the pistons of the brakes on the front and rear axles.
The travel of the oil from the brake group to the service brake pistons on the axles occurs through separate
circuits for the rear and front axles; each circuit is divided to actuate the brake pistons located on axle central
body.
The service brake control solenoid valve incorporated in the brake pedal allows, when actuated by the
appropriate switch located in the cab on the dashboard, the permanent actuation of the service brakes taking
oil from a service accumulator and sending it to a control plunger actuating the pedal.
The brake discs are an oil bath multiple disc type.
Two pressure switches, connected to the brake group, are used to operate the stop lights (setting 5 bar) and
to operate the brake failure indicator (pressure switch setting 90 bar).
60406991
21599
 1 - Front axle
2 - Rear axle
3 - From transmission valve
4 - Hydraulic reservoir
5 - Brake pilot system pump
6 - Steering pump
7 - To steering system
8 - Pilot system filter
14 9 - Brake pedal group
10 - Stop light pressure switch
1/6 15/32 1/6 11 - Accumulators
12 - Brakes system low pressure
indicator pressure switch
13 - To priority valve
14 - Pressure sensor

H=1/1.96
BRAKES SYSTEM EX135W

L=1/7.445

1/6 15/32 1/6

F7687
HS7-5-2

21599 60406991
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HS7-5-3

BRAKES SYSTEM EX135W

5.3 OPERATION OF BRAKE PEDAL VALVE

The hydraulic power coming from the brake pilot system pump and the pilot system filter, reaches inlet port
P of the brake pedal valve.
The brake pedal valve is of a modular type and incorporates the accumulators charge valve A (12) brake
modules (13), service brake control solenoid valve (14), brake pedal, service brake control cylinder and uses
a small portion of energy from the hydraulic system of the machine, letting the oil delivery available for the
actuators of the pilot system.
This function is obtained by charge valve (A) taking automatically the oil to charge the hydraulic accumulators.
Its technical characteristics have as a result an increase in the braking power and a reduction of the effort on
the pedal.
The braking pressure is regulated by modules connected to the braking circuits.
The system is already perfectly adjusted and set, thus no regulations are required.

10
11
16
2 R R R 17
F
14 9
Z
12
X 15 90 bar

70 bar T2 13
6 P
P
4 8
5 1
T1' 13 B
5 bar
7
70 bar T1
140 bar
70 bar

3 F8946

1 - Feeding to the actuators

2 - Connection for service braking
3 - Discharge to reservoir
4 - Connection to pressure switch
5 - Stop lights pressure switch
6 - Delivery to front axle
7 - Delivery to rear axle
8 - Feeding from pump
9 - Brakes system low pressure indicator pressure switch
10 - Accumulator
11 - Service accumulator
60406991

12 - Accumulator charge valve (A)

13 - Brake modules
21599

14 - Service brake control solenoid valve (X)

15 - Service brake control cylinder
16 - Brake pedal
17 - Pressure sensor
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HS7-5-4

BRAKES SYSTEM EX135W

5.3.1 OPERATION OF ACCUMULATORS CHARGE CIRCUIT

The accumulators are fed with a priority over the other actuators, by the accumulator charge valve mounted
after the pump.
During the charging phase, the charge valve operates as a differential delivery divider ensuring the feeding
of the actuators of the pilot system.
Once the accumulator charge pressure is reached, the charge valve directs the entire delivery of the pump
to the actuators of the pilot system.
The pressure in the accumulators circuit is kept constant within the tolerance range of the charge valve.
The two service braking circuits are protected from each other by check valves, so that, in case of failure of
one of them, the other is perfectly operational.
The charge condition of the accumulator is monitored by the brake low pressure switch and by a pressure
gauge located on the steering column. They both indicate that brake pressure is low, so that the operator
receives a visual indication in case there is a lack of energy, such as the engine is inoperative and signals,
also, after the starting of the vehicle, the efficiency of the brakes system.

5.3.2 OPERATION OF THE SERVICE BRAKING CIRCUIT

When the service brake is actuated, the valve made of the two brake modules controlling the two brake circuits,
regulates the pressure in the brake circuits proportionally with the actuating force, both on the front and rear
axles.
At the end of the braking phase, the oil returns to the reservoir.
In case of failure of one braking circuit, the other circuit, through the mechanical contact of the two pistons of
the brake module, continues to brake, ensuring the perfect functionality of the two accumulators.
The actuating force remains unchanged.
At each actuation of the service brake, a pressure switch (set at 5 bar) monitors the pressure in the rear axle
brake circuit and switches ON the stop lights.

5.3.3 OPERATION OF THE SERVICE BRAKE CONTROL SOLENOID VALVE

When the service brake actuating switch is actuated, the service brake control solenoid valve is energised,
thus, by moving the spool, the service accumulator charging pressure is connected to the service brake control
cylinder.
The movement of the service brake control piston controls the two brake modules that connect the
accumulators to the front and rear axle brakes circuits.
When the service brake button is actuated, the axle lock is automatically actuated.
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HS7-5-5

BRAKES SYSTEM EX135W

5.3.4 DESCRIPTION AND OPERATION OF THE BRAKE SYSTEM ACCUMULATORS

The accumulators, of a membrane type, ensure a certain quantity of actuations of the brakes with engine
inoperative.
The membrane accumulator is made of a pressure resistant steel container, having, inside, a membrane made
of elastic material as separation element. The membrane is locked by a ring nut between the lower and higher
side of the body.
In the central lower part of the membrane, a metallic disc is incorporated, to prevent its exit through the fluid
inlet port.
The accumulators are filled, from the upper part, by a nitrogen pre-load at 50 bar, whereas the lower part is
connected to port R of the brake pedal group.

1 - Gas valve
2 - Container
3 - Membrane
4 - Valve mushroom
5 - Oil side connection

Without hydraulic pressure, the membrane, loaded on the gas side at the pre-load pressure P0 , is leaning
against the inner surface of the accumulator and the mushroom closing the fluid passage.
When hydraulic pressure is applied to the brake pedal group, once it exceeds the pre-load pressure by
pressing the nitrogen, the mushroom is lifted and hydraulic oil enters the accumulator. The useful quantity of
oil results from the difference between the gas volume and the minimum and maximum operating pressure.
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HS7-5-6

BRAKES SYSTEM EX135W

5.3.5 PRESSURE SWITCHES - BRAKES SYSTEM

The pressure switches on the brakes system are used to monitor failures of the brakes system and cause the
switches ON of the stop lights.
The pressure switches are made of an oil resistant membrane element, silver plated electrical contacts, body
with faston terminals, balance and pressure setting springs.
The brakes system failure monitoring pressure switch is set at 90 bar, whereas the stop light pressure switch
is set at 5 bar.
For the regulation of the pressure to be monitored, it is necessary to have available a small screwdriver and
turn the regulation screw V, ensuring that the spring is not totally pressed.
The electrical connection and the inner elements are protected against infiltrations of water and dust by a
protection boot.

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HS7-6-1

OPERATION OF CIRCUITS EX135W

6. OPERATION OF CIRCUITS

6.1 GENERALITIES

The main pump feeds the right body (M7) of the 5 section control valve.
The secondary pump feeds the left body (M8) of the 2 section control valve.
The right side of the 5 section control valve is of a closed center type, whereas the 2 section left side control
valve is of an open center type.

The paragraphs below describe the operation of the hydraulic circuits divided in accordance with the controls
of the hand and pedal pilot valves.
In the diagrams of these paragraphs the flow of the main hydraulic feeding is shown in continuous bold lines,
whereas the return of the main hydraulic feeding to the reservoir is indicated in dashed bold lines.

6.1.1 OPERATION OF PILOT CONTROL AUTO IDLE

P6

F8947
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HS7-6-2

OPERATION OF CIRCUITS EX135W

6.2 CIRCUIT WITH CONTROLS IN NEUTRAL

Under the conditions with hand and pedal pilot valves in neutral position, the hydraulic oil coming from the main
pump reaches the right body of the control valve, where it is intercepted by the position of the five spools.
The hydraulic oil coming from the secondary pump, reaches the two spools of the left body of the control valve,
it passes them in the neutral position, and, through the check valve set at 5.5.bar, returns to the reservoir
through the oil cooler.

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HS7-6-3

OPERATION OF CIRCUITS EX135W

CIRCUIT WITH CONTROLS IN NEUTRAL
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F11059 - EX135W -EX165W

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HS7-6-4

OPERATION OF CIRCUITS EX135W

6.3 BOOM CIRCUIT

6.3.1 RAISING THE BOOM

When the lever of the right manual pilot valve is moved to boom raise position, the piloting oil flows to the control
of the spool of the raise section of the control valve.
The hydraulic oil coming from the main pump, when the spool (for raise) moves, is sent to the bottom of the
boom cylinder pushing out the rod.
The hydraulic oil flowing out the rod side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

6.3.2 LOWERING THE BOOM

When the lever of the right manual pilot valve is moved to boom lowering position, the piloting oil flows to the
control of the spool of the raise section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the head of the boom cylinder
pushing in the rod.
The hydraulic oil flowing out the bottom side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

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HS7-6-5

OPERATION OF CIRCUITS EX135W

BOOM CIRCUIT
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F11060 - EX135W -EX165W

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HS7-6-6

OPERATION OF CIRCUITS EX135W

6.4 DIPPER STICK CIRCUIT

6.4.1 EXTENSION OF STICK

When the lever of the left manual pilot valve is moved to stick extension position, the piloting oil flows to the
control of the spool of the digging section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the bottom of the digging
cylinder pushing out the rod.
The hydraulic oil flowing out the bottom side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

6.4.2 RETRACTING THE STICK

When the lever of the left manual pilot valve is moved to stick retract position, the piloting oil flows to the control
of the spool of the digging section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the head of the digging cylinder
pushing in the rod.
The hydraulic oil flowing out the bottom side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

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HS7-6-7

OPERATION OF CIRCUITS EX135W

DIPPER STICK CIRCUIT
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F11061-EX135W-EX165W
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HS7-6-8

OPERATION OF CIRCUITS EX135W

6.5 BUCKET CIRCUIT

6.5.1 OPENING THE BUCKET

When the lever of the right manual pilot valve is moved to bucket opening position, the piloting oil flows to the
control of the spool of the bucket section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the head of the bucket cylinder
pulling in the rod.
The hydraulic oil flowing out the bottom side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

6.5.2 ROLLING-IN THE BUCKET

When the lever of the right manual pilot valve is moved to bucket rolling-in position, the piloting oil flows to the
control of the spool of the bucket section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the bottom of the bucket
cylinder pushing out the rod.
The hydraulic oil flowing out the head side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

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HS7-6-9

OPERATION OF CIRCUITS EX135W

BUCKET CIRCUIT
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F11062-EX135W-EX165W
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HS7-6-10

OPERATION OF CIRCUITS EX135W

6.6 POSITIONER ARM CIRCUIT

6.6.1 EXTENDING THE POSITIONER ARM

When the positioner arm selector solenoid actuation button (located on the right hand pilot valve) is pressed,
the right pedal pilot valve is pushed into extension position, the piloting oil flows to the control of the spool of
the positioner section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the head of the positioner
cylinder pulling in the rod.
The hydraulic oil flowing out the bottom side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

6.6.2 RETRACTING THE POSITIONER ARM

When the positioner arm selector solenoid actuation button (located on the right hand pilot valve) is pressed,
the right double pedal pilot valve is pushed into rolling-in position, the piloting oil flows to the control of the spool
of the positioner section of the control valve.
The hydraulic oil coming from the main pump, when the spool moves, is sent to the bottom of the positioner
cylinder pushing-out the rod.
The hydraulic oil flowing out the head side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.

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HS7-6-11

OPERATION OF CIRCUITS EX135W

POSITIONER ARM CIRCUIT
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F11063-EX135W-EX165W
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HS7-6-12

OPERATION OF CIRCUITS EX135W

6.7 TRAVEL CIRCUIT

6.7.1 FORWARD SPEED

After disengaging the parking brake by actuating the button on the central dashboard, by pushing the pedal
into forward travel position, the piloting oil flows to the control of the spool of the travel section of the control
valve.
The hydraulic oil coming from the main pump, is sent to port A of the travel motor.
After rotating the motor and transferred the power to the shaft, the hydraulic oil flowing out port B returns to
the spool in the return duct of the control valve and reaches the cooler and total flow filter to the reservoir.

6.7.2 REVERSE SPEED

After disengaging the parking brake by actuating the switch on the central dashboard, by pushing the pedal
pedal into reverse travel position, the piloting oil flows to the control of the spool of the travel section of the
control valvehrottle control box, that positions itself in the pre-selected speed, if the “automatic idle” function
is actuated.
The hydraulic oil coming from the main pump, is sent to port B of the travel motor.
After rotating the motor and transferred the power to the shaft, the hydraulic oil flowing out port A returns to
the spool in the return duct of the control valve and reaches the cooler and total flow filter to the reservoir.

Note: Only in case of forward or reverse travel with engine speed selected in mode P, the pressure switches
relative to the travel, by closing, send a signal to the engine speed control box to increase the engine
speed from 2100 to 2330 rpm.

6.7.3 TRAVEL MOTOR BRAKE VALVE C2

For the operation of C2 valve the following requirements should be met:

- switch in position "hare";
- second hand speed;
- travel pedal released in forward gear.
If this situation lasts for ≥ 5 seconds, always in the same conditions (second speed connected, forward gear
and pedal on neutral), in order to avoid hydraulic liquid overheating in a closed circuit, the check card controls
solenoid valve C2 for brake check that is disenergized and returns to rest position.
The solenoid valve C2 in disenergized conditions, puts in connection outlet MB with inlet G, via a piping
outside travel motor.
With the input of this pressure signal to engine port G, the automatic controller is shifted to the max.
displacement position (reduced speed) thus increasing the travel motor braking action.
When the travel motor is operating with transmission in first speed, solenoid valve C2 is not disenergized, as
the motor braking action, with pedal in neutral position, is enough for machine control. Solenoid valve C2,
remaining energized, cuts off the connection between outlet MB and inlet G and does not allow a
supplementary control to motor displacement.

60406991
The energization/disenergization of solenoid valve C2 is controlled by check card and APC50 microprocessor
that feed transmission position (first or second) and pedal position (neutral or operated by travel line pressure
switches).

21599
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HS7-6-13

OPERATION OF CIRCUITS EX135W

TRAVEL CIRCUIT
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F11064-EX135W-EX165W
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HS7-6-14

OPERATION OF CIRCUITS EX135W

6.8 BLADE (SMALL DOZER) BLADE CONTROL

6.8.1 LOWERING THE BLADE

When the blade selector solenoid actuation button (located on the right hand pilot valve) is pressed, and the
lever of the left hand pilot valve is in forward position, the piloting oil flows to the control of the spool of the blade/
stabilisers of the control valve.
The hydraulic oil coming from the secondary pump, when the spool moves, is sent to the bottom of the blade
cylinder pushing-out the rods and lowering the blade.
The hydraulic oil flowing out the head side of the cylinders returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.
Two piloted double cut-off valves are mounted on the blade cylinders to prevent any unintentional movement.

6.8.2 RAISING THE BLADE

When the blade selector solenoid actuation button (located on the left hand pilot valve) is pressed, and the
lever of the left hand pilot valve is in reverse position, the piloting oil flows to the control of the spool of the blade/
stabilisers of the control valve.
The hydraulic oil coming from the secondary pump, when the spool moves, is sent to the head of the blade
cylinder pulling-in the rods and raising the blade.
The hydraulic oil flowing out the bottom side of the cylinders returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.
Two piloted double block valves are mounted on the blade cylinders to prevent any unintentional movement.

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HS7-6-15

OPERATION OF CIRCUITS EX135W

BLADE (SMALL DOZER) CONTROL CIRCUIT
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F11065 - EX135W -EX165W

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HS7-6-16

OPERATION OF CIRCUITS EX135W

6.9 SIDE STABILISERS CONTROL CIRCUIT

6.9.1 LOWERING THE STABILISER

Note: When the button B of the left hand pilot valve is pressed, the actuation of the left side stabiliser is
approved.
When the button C of the right hand pilot valve is pressed, the actuation of the right side stabiliser
is approved.

If the machine is equipped with 4 side stabilisers, the button B of the left hand pilot valve approves
the temporary actuation, at the same time, of the left front and rear side stabilisers, and, in the same
manner, the button C approves the actuation for the right front and rear side stabilisers.

Keeping the selected button pressed, while the left hand pilot valve is moved forward, the piloting oil flows to
the control of the spool of the blade/stabilisers of the control valve.
The hydraulic oil coming from the secondary pump, when the spool moves, is sent to the bottom of the
stabiliser cylinder selected pushing-out the rod of the cylinder.
The hydraulic oil flowing out the head side of the cylinders returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.
Two piloted double cut-off valves (one per cylinder) are mounted to prevent any unintentional movement.

6.9.2 RAISING THE STABILISER

Keeping the selected button pressed, while the left hand pilot valve is pulled backward, the piloting oil flows
to the control of the spool of the blade/stabilisers of the control valve.
The hydraulic oil coming from the secondary pump, is sent to the head of the stabiliser cylinder selected
pushing-in the rod of the cylinder.
The hydraulic oil flowing out the bottom side of the cylinder returns to the spool in the return duct of the control
valve and reaches the cooler and filter to the reservoir.
Two piloted double cut-off valves (one per cylinder) are mounted to prevent any unintentional movement.

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HS7-6-17

OPERATION OF CIRCUITS EX135W

SIDE STABILISERS CONTROL CIRCUIT
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F11066 - EX135W -EX165W

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HS7-6-18

OPERATION OF CIRCUITS EX135W

6.10 TURRET SWING CIRCUIT

6.10.1 CLOCKWISE SWING

When the lever of the left hand pilot valve is moved to the right into the turret clockwise swing position, the
piloting oil flows to the control of the spool of the turret swing of the control valve.
The piloting oil, besides controlling the spool, is also sent to the selector valve to control the unlocking of the
negative brake on the reduction unit inlet.
With the pilot valve actuated, piloting pressure is also sent to the pressure relief valve mounted on the swing
motor, relative to the swing direction, changing the pressure setting to 320 bar.
The hydraulic oil coming from the secondary pump is sent to the inlet port “B” of the swing motor and, after
rotating it, exits from outlet port “A” to return to the spool in the return duct of the control valve and reaches
the cooler and filter to the reservoir.
When returning the lever of the left pilot valve in neutral, the spool moves to neutral diverting the delivery of
the swing motor to the neutral circuit, and removes also the piloting pressure to the pressure relief valve (B
side). The brake and modulating valve mounted on side A operates as braking valve at a value of 180 bar.
The intervention of the mechanical brake is timed by restrictions.
With the pilot valve in neutral position, the return oil crossing the open center duct of the control valve is applied
to the inlet port S of the swing motor to feed it during the braking phase, when the pressure relief valves operate
as anticavitation devices.

6.10.2 ANTICLOCKWISE SWING

When the lever of the left hand pilot valve is moved to the left into the turret anticlockwise swing position, the
piloting oil flows to the control of the spool of the turret swing of the control valve.
The piloting oil, besides controlling the spool, is also sent to the selector valve to control the unlocking of the
negative brake on the reduction unit inlet.
With the pilot valve actuated, piloting pressure is also sent to the pressure relief valve mounted on the swing
motor, relative to the swing direction, changing the pressure setting to 320 bar.
The hydraulic oil coming from the secondary pump is sent to the inlet port “A” of the swing motor and, after
rotating it, exits from outlet port “B” to return to the spool in the return duct of the control valve and reaches
the cooler and filter to the reservoir.
When returning the lever of the left pilot valve in neutral, the spool moves to neutral diverting the delivery of
the swing motor to the neutral circuit, and removes also the piloting pressure to the pressure relief valve (A
side). The brake and modulating valve mounted on side B operates as braking valve at a value of 180 bar.
The intervention of the mechanical brake is timed by restrictions.
With the pilot valve in neutral position, the return oil crossing the open center duct of the control valve is applied
to the inlet port S of the swing motor to feed it during the braking phase, when the pressure relief valves operate
as anticavitation devices.

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HS7-6-19

OPERATION OF CIRCUITS EX135W

TURRET SWING CIRCUIT
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F11068 - EX135W -EX165W

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HS7-6-20

OPERATION OF CIRCUITS EX135W

NOTES:

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HS7-7-1

TRAVEL SYSTEM EX135W

7. TRAVEL CIRCUIT

7.1 DESCRIPTION

The travel system includes the travel hydraulic motor control circuit, the transmission control circuit and the
parking brake control circuit (see fig. page 7-3).

7.2 TRAVEL HYDRAULIC MOTOR CONTROL CIRCUIT

- The travel circuit is used to control the rotation of the travel hydraulic motor.
Actuating the pedal the position of the spool relative to the travel function on the right body of the control
valve (M7) is defined.
This control occurs under the condition that:

a) When parking brake is released, solenoid valve A0 is energized and allows pilot control oil to reach the
pedal.

b) Positioner arm selector solenoid valves B3 and B4 are not energised (if these solenoid valves are
energised, the piloting hydraulic pressure will be directed to the spool of the control valve for the
positioner arm control instead of travel).

The hydraulic pressure of the main pump with the opening of the travel spool on the control valve is directed
to port A of the travel motor (or inlet port B) for forward speed (or for reverse) depending upon pedal position.
The hydraulic feeding will rotate the motor at a speed proportionate to the position of the pedal and the load
to which the motor is subject.
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HS7-7-2

TRAVEL SYSTEM EX135W

- In fact, the motor is equipped with a displacement automatic regulator, as a function of the operating
pressure. The regulator monitors the operating pressure at inlet port A or B and controls the position of
the bent axis, thus the displacement of the motor from a minimum position (minimum torque - maximum
speed) to a maximum displacement (maximum torque - minimum speed).

- In detail, the delivery pressure is connected to the spool of the regulator in contrast with the setting
spring.
When the pressure exceeds the setting of the spring, it moves the spool and connects the inlet pressure
with the positioning cylinder. This, with its movement, will change the displacement of the motor from
minimum to maximum.
Changing the displacement, the pressure decreases, thus re-establishing the equilibrium.

- The regulator is equipped with an additional piloting for the control of the plate to maximum displacement,
through the sending of a piloting pressure to inlet “X”.
This external piloting occurs by energising solenoid valve A3 controlling the travel speed variation, located
in the services solenoid valves group.
If the normal speed (rabbit) switch on the central dashboard is selected, solenoid valve A3 is not energised
and the piloting pressure does not reach the travel motor.
If, on the contrary, the low speed (turtle) switch on the central dashboard is turned, solenoid valve A3 is
energised allowing the passage of the piloting pressure reaching inlet X of the travel motor.
This piloting pressure is applied to the regulator controlling valve in addition to the signal monitoring the
operating pressure, causing the movement of the axis toward maximum displacement.
Under these conditions, with additional piloting ON, the rotation speed of the engine will be lower than
the speed under normal conditions.

- Under operating conditions of the travel motor in forward speed (rabbit) and mechanical transmission in
second gear, if the pedal is returned to neutral, the travel motor is dragged by the inertia of the machine
and operates as a pump. Under these conditions, the travel spool of the control valve moves to neutral
position. This, being prevented from using the pressure of the hydraulic oil of the main circuit, since it is
dragged by the inertia of the machine, sucks oil from the return through the pressure relief valve of the
travel motor, thus being subject to a braking action against the rotation.
During this phase, the pressure relief valve operates as an anticavitation valve, by-passing inlet and
outlet, to avoid damages to the rotating components of the motor.
If this condition continues for 5 seconds, always under the same conditions (second gear engaged,
forward speed (rabbit) and pedal in neutral), in order to avoid possible overheating of the hydraulic fluid
operating in a closed circuit, the check function commands the braking control solenoid valve C2 to go
OFF and move to rest position.
Solenoid valve C2 in non energised position, connects, through a pipe outside the travel motor, outlet
MB with inlet G.
With the entry of this pressure signal at port G of the motor, the automatic regulator is commanded to
move into maximum displacement position (slow speed) thus increasing the braking action of the travel
motor.
Under operating conditions of the travel motor with transmission in first gear, solenoid valve C2 is not de-
energised, since the braking action of the motor, with pedal in neutral position, is sufficient to control the
machine. Solenoid valve C2 staying energised, cuts the connection between outlet MB and inlet G allowing
an additional control by the displacement regulator of the motor.
The energising/de-energising of solenoid valve C2 is controlled by a check function and the APC50
60406991

micro processor that monitor the position of the transmission (first or second gear) and the position of the
pedal (neutral or actuated by the travel line pressure switches).
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HS7-7-3

TRAVEL SYSTEM EX135W

TRAVEL BLOCK DIAGRAM

P 3
P1 2
20 19
1

17 18

P 3 2 1 5 4

21 7
1 2
9 22
a3 P1

6
b3 A3 B3
14
11 2
12
1
3
17 10
8 4

16 13
15

F7249

1 - Diesel engine 12 - Selector/transmission (first/second) line

2 - Main hydraulic pump 13 - Parking brake control line
3 - Secondary hydraulic pump 14 - Travel motor (forward/reverse) control line
4 - Brakes pilot system pump 15 - Rear axle
5 - Steering pump 16 - Transmission group
6 - Control valve 17 - Travel speed (low-turtle/normal-rabbit) control line
7 - Front axle 18 - Brake valve
8 - Travel hydraulic motor 19 - Priority valve
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9 - Accumulator 20 - Services solenoid valves group

10 - Transmission control line 21 - Travel control pedal
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11 - Clutch control line 22 - Single direction valve

Note: The center joint has been omitted to simplify the diagram.
 5 1 Diesel engine
T1
2 Main hydraulic pump
T
12 3 Brakes/pilot system pump
7 +3 4 Pilot system filter
35-3 bar

P 5 Services solenoid valves

8
22 A3 A0
13
6 group
10
P1 6 Solenoid valve A3
5

12 l/min.
7 To blade/stabiliser selector
4 21 solenoid valve
(B) 2 8 Slow/fast speed control line
17
A3 B3 9 Control valve
(P) 1
B S A 10 Travel hydraulic motor group
9 11 Solenoid valve C2
30 12 To hydraulic reservoir
13 Services solenoid valves
B accumulator
Ø 1.2 Ø 1.2

A B
C2 18 14 Transmission and rear axle
350 bar
assembly
11 P 15 Hydraulic reservoir
P T
T
16 Steering pump
G 17 Priority valve

Ø 0.8
X P
12 18 Brake valve group
TRAVEL SYSTEM EX135W

19 Clutch control cylinder

MB B 4 20 Clutch
MA
22 21 To transmission control
PB PS circuit
C D A B
19 B3 B4 2 22 Center joint
1 15
P2 P1 T
3 16 23 Kick-down pressure switch
20 23 24 Pressure switch 3 bar
14 T Forward travel auto idle and engine
24 S
25 speed increase
2 1
25 Pressure switch 3 bar
29 Reverse travel auto idle and engine
F11150
T P
speed increase
29 Pedal
12 30 Unidirectional valve
HS7-7-4

19400 60406991
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HS7-7-5

TRAVEL SYSTEM EX135W

7.3 TRANSMISSION CONTROL CIRCUIT

- The transmission control circuit uses the pressure of the hydraulic oil provided by the pilot system/brakes
pump.
Pressurised oil, after going through the brake valve, reaches the priority valve where the flow is divided,
ensuring a fixed flow to the piloting system of 12 liter/minute. The pressure of the piloting hydraulic oil,
after charging the transmission accumulator, reaches the transmission control solenoid valves group.
The transmission control solenoid valves group includes three solenoid valves A, B and C that are
electrically controlled by the APC50 micro-processor.

- The transmission, of an automatic type, has two speeds and the shift from one to the other is provided
only when the clutch is disengaged.
The control of the clutch and the control of the speed shift cylinder are of a mechanical spring actuated
and hydraulic disengagement lock type.
The speed direction shift is provided by the movement of a rod connected to the speed shift cylinder.
When pressure is applied to the speed shift cylinder, the shift rod engaging the first gear is moved;
without hydraulic pressure, the springs move the speed shift cylinder, thus the shift rod engages the
second gear.
When hydraulic pressure is applied to the clutch cylinder the latter is disengaged; without hydraulic
pressure, the springs of the clutch control cylinder engage the clutch.
The electric signals coming from the APC50 micro-processor allow the speed direction shift by actuating
in sequence, solenoid valves C and B.

a) Energising the clutch control solenoid valve C.

b) De-energising (or energising) the speed shift control solenoid valve B.
c) De-energising solenoid valve C.

When energising solenoid valve C, the hydraulic pressure reaches the clutch control cylinder, that, opposing
the action of the springs, disengages the clutch.
When de-energising (or energising) solenoid valve B the hydraulic pressure delivered to the speed shift
cylinder moving the speed shift rod is intercepted (with hydraulic pressure the first gear is engaged,
without hydraulic pressure the second gear is engaged).

When solenoid C is de-energised, the hydraulic pressure to the clutch control cylinder is intercepted, and
the springs, not being opposed any further, engage again the clutch.
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HS7-7-6

TRAVEL SYSTEM EX135W

- The electric signals provided by the APC50 micro-processor are processed as a function of the signals
that are sent by the transmission system, i.e.:
Position signals of the transmission shift control lever on steering column.

Signals for transmission lever position: first, automatic, second.

Position signal of the gear engaged.
Transmission rotation speed signal.

The sequence of energising of solenoid valves C (clutch control) and B (speed shift) occurs automatically
with machine in motion, as a function of the speed monitored on the final gear of the transmission if it is
increasing or decreasing.
If the rotation speed is increasing around 520 rpm, the APC50 micro-processor provides signals for the
gear shifting from first to second gear.
If the rotation speed decreases around 20 rpm, the APC50 micro-processor provides signals for the gear
shifting from second to first gear.
These values are applicable only under the condition that the pedal pilot valve is moved up to about half-
stroke, so that the piloting pressure does not exceeds 20 bar, being the operating limit of the kick-down
pressure switch.

- The kick-down pressure switch is mounted on the pilot system pressure line, after the pedal pilot valve,
and on the forward travel control line.
When the pedal pilot valve is actuated toward full stroke and the piloting pressure exceeds 20 bar, the
contacts of the kick-down pressure switch are commuted, providing a signal to the APC50 micro-processor.
The latter, by considering the movement of the pedal pilot valve toward full stroke as an intention of the
operator to obtain an acceleration or an higher break-away, changes the threshold of the automatic
intervention of the transmission.
Consequently, the sequence of the gear shifting will be controlled by the APC50 micro-processor in the
following manner:

a) With rotating speed increasing around 550 rpm (instead of 520 rpm with pressure below 20 bar, kick-
down pressure switch not actuated) the micro-processor controls the sequence for the shifting from first
to second gear.

b) With rotating speed decreasing around 220 rpm (instead of 20 rpm with pressure below 20 bar, kick-
down pressure switch not actuated) the micro-processor controls the sequence for the shifting from
second to first gear.

With the change of the intervention threshold of the automatic transmission due to the intervention of the
kick-down pressure switch, the machine will obtain an acceleration and/or different break-always, allowing
a more flexible driving behaviour related to the speed or traffic conditions.

- At the inlet of the transmission control solenoid valves group a 0.75 liter and 8 bar pre-charge pressure
accumulator is mounted.
This accumulator related to the transmission circuit has the purpose of ensuring always, with engine
operative, that the pressure of the transmission control solenoid valves group never diminish below the
pre-load value of the accumulator. In fact, the transmission does not ensure a correct disengagement of
60406991

the clutch or speed shifting in case the pressure drops.

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HS7-7-7

TRAVEL SYSTEM EX135W

TRANSMISSION CONTROL CIRCUIT

11

10

12 C
H=1/1.96 6
L=1/7.445 13

19 7

14 B
22
1 2 12

3
15
16 3
D 9 8 5
2

17 17 1
0
4 22 B

4
20 A B C P
1.6 18 15/32 18 1.6

3
21

2
1

F11152

1 - Hydraulic oil reservoir 12 - Clutch control cylinder

2 - Pilot system and brakes pump 13 - Clutch
60406991

3 - Pilot system filter 14 - Speed shift cylinder

4 - Brake valve group 15 - Speed ON switch
5 - Priority valve 16 - Speed sensor
19400

6 - To services solenoid valves group 17 - Disc brakes

7 - Center joint 18 - Service brake pistons
8 - Transmission accumulator 19 - Parking brake piston (negative)
9 - Transmission control solenoid valves group 20 - Differential
10 - Travel hydraulic motor 21 - To brake valve group
11 - Transmission and rear axle assembly 22 - Single direction valve
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HS7-7-8

TRAVEL SYSTEM EX135W

7.4 PARKING BRAKE CONTROL CIRCUIT

- The machine is equipped, on the rear axle in the gearbox, with an hydraulically controlled parking brake,
electrically actuated.
The parking brake, also called negative brake, is of a spring actuated and hydraulically released type.
Without hydraulic pressure sent to the parking brake piston, the springs located inside the piston itself
keep the discs engaged in a braking action, whereas with hydraulic pressure applied to the piston, the
action of the springs is neutralised, thus the braking action is eliminated.

- When operating the parking brake engagement switch on the dashboard, a negative signal is cut off to
the APC50 and disenergizes solenoid valve A0 located in the services solenoid valve group.
The APC50 does not allow the energising of solenoid valve “A” of the transmission solenoid valves
group. This intercepts the hydraulic pressure of the brakes pilot system to the parking brake piston.
The inner spring in the piston, not being antagonised any further by the hydraulic pressure, will extend,
thus developing their braking action on the discs on the gearbox.
The disenergizing of solenoid valve A0 will preclude the piloting hydraulic pressure from reaching the
pedal pilot valve, thus inhibits the travel function while the parking brake is engaged.
When the parking brake switch is actuated, the transmission lock is automatically engaged.

- When disengaging the parking brake through the switch, a negative signal is sent to control unit APC50
which will energise solenoid valve “A” located in the transmission solenoid valves group. The pressure
switch located on parking brake line closes and solenoid valve A0 is energized, thus the hydraulic pressure
can reach the parking brake piston and by allowing the action on the inner springs, will free the discs,
eliminating the braking action on the gearbox.
The solenoid valve A0 located in the services solenoid valves group will allow the piloting pressure to
reach the pedal, thus allowing the travel of the machine.

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HS7-7-9

TRAVEL SYSTEM EX135W

PARKING BRAKE CONTROL CIRCUIT

12
T1
+3
35-3 bar 11
T

P
10 13

P1

14
H=1/1.96 C
L=1/7.445

19

7
B
22
1 2 12
3

3
9 8 5
2

17 1
0 22
4 B

17 4
20 A B C P
1/6 18 15/32 18 1/6

3
21

2
1

F11153

1 - Hydraulic oil reservoir 11 - Pilot system accumulator

2 - Pilot system and brakes pump 12 - Services solenoid valves group
60406991

3 - Pilot system filter 13 - Solenoid valve A0

4 - Brake valve group 14 - To travel pilot valve
5 - Priority valve 17 - Disc brakes
19400

7 - Center joint 18 - Service brake pistons

8 - Transmission accumulator 19 - Parking brake piston (negative)
9 - Transmission control solenoid valves group 20 - Differential
10 - Transmission and rear axle assembly 21 - To brake valve group
22 - Single direction valve
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HS7-7-10

TRAVEL SYSTEM EX135W

NOTES:

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HS7-8-1

HYDRAULIC SYSTEM DIAGRAM EX135W

HYDRAULIC SYSTEM DIAGRAM

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HS7-8-2

HYDRAULIC SYSTEM DIAGRAM EX135W

8. HYDRAULIC SYSTEM DIAGRAM

HYDRAULIC SYSTEM PARTS

1. Diesel engine 36. Cylinders for dozing blade and/or stabilizers

2. Main pump and swing unit (optional)
3. Brakes pump and power steering unit 37. Travel motor
4. Oil reservoir 38. Slewing motor
5. Return oil filter 39. Bucket cylinder
6. Radiator 40. Digging cylinder
7. Valve 41. Lifting cylinders
8. Solenoid valve for clamshell bucket swing 42. Articulation cylinder
9. Hydraulic steering unit 43. Hammer valve
10. Delivery oil filter (optional)
11. Pressure switch for insufficient brake charge 44. Priority valve for controls feeding
pressure 45. Swing brake
12. Accumulator, servo-controls 46. Gearbox accumulator
13. One-way throttling valves 47. Inlet block and discharges
14. Parking brake 48. Antidrop valve
15. Transmission control valve (optional)
16. One-lever joystick 49. Grass-cutter
17. Foot control (optional)
18. Braking system accumulators 50. Hammer
19. Transmission (optional)

20. Control valve 51. Clamshell bucket

(optional)
21. Solenoid valve
52. Selection valve
22. Stop lights pressure switch
(optional)
23. Service solenoid valves
53. Valve
24. Braking system valve
54. Pressure intakes
25. Slewing valve
55. Crusher
26. Travel valve
(optional)
27. Selection valve for dozing blade/stabilizers
56. Crusher valve
(optional)
(optional)
28. Axle lock-out valve
57. Accumulator charge pressure sensor
29. Solenoid valve for travel engine braking
30. Front steering steering
31. Front axle with brake
60406991

32. Rear axle with brake and gearbox

33. Lock-out valve
21599

(optional)
34. Axle lock-out cylinders
35. Cocks
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HS7-8-3

HYDRAULIC SYSTEM DIAGRAM

Sol. 0
60406991
19400

F11066 - EX135W -EX165W

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HS7-8-4

OPERATION OF CIRCUITS EX135W

NOTES:

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21599
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INDEX EX135W - 8 - 1

SECTION 8 ELECTRICAL SYSTEM

INDEX

Group 1 - SAFETY RULES .......................................................................................... ES8-1-1

1.1 Safety rules

Group 2 - SPECIFICATIONS AND DATA .................................................................... ES8-2-1

2.1 Specifications and data

Group 3 - LOCATION AND FUNCTIONS OF COMPONENTS ................................... ES8-3-1

3.1 Construction
3.2 Location of electrical components
3.3 Instruments and controls

Group 4 - ARRANGEMENTS AND OPERATION ........................................................ ES8-4-1

4.1 Electrical system

Group 5 - ELECTRONIC CONTROL UNITS AND DIODES ........................................ ES8-5-1

5.1 Generalities
5.2 APC50 electronic unit
5.3 Electronic unit
5.3 Throttle piston control electronic unit (SMC)

Group 6 - ELECTRIC COMPONENTS ........................................................................ ES8-6-1

60406991

6.1 Throttle control

6.2 Center joint
21599

6.3 Batteries
6.4 Alternator
6.5 Starter motor

(continued)
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INDEX (continued)

Group 7 - CONTROL LINE AND WIRING HARNESSES .......................................... ES8-7-1

7.1 Pilot lever control

7.2 Switch panel control
7.3 Brake pedal control
7.4 Steering column controls

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ES8-1-1

SAFETY RULES EX135W

1. SAFETY RULES

1.1 SAFETY RULES

WARNING

When working on the electrical system, always wear

protective glasses and remove all rings, wrist watches
and every other metal jewellery.

WARNING DISCONNECT

Prior to any inspection or repair of electrical

components, DISCONNECT GROUND WIRE “A” from
the negative terminal “B” of the battery.
Disconnect wire “C” from the positive terminal “D”.

EARTH LINE

WARNING

NEVER PLACE METALLIC OBJECTS on the battery,

to prevent short circuits.

WARNING

GASES GENERATED BY THE BATTERY ELECTROLYTE ARE FLAMMABLE. Avoid sparks and free flames
near the batteries. During recharging, the emission of gas is intensified.

WARNING
60406991

GASES GENERATED BY THE BATTERIES ARE DANGEROUS if they contact the skin or any material.
21599
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ES8-1-2

SAFETY RULES EX135W

NOTES:

21599 60406991
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ES8-2-1

SPECIFICATIONS AND DATA EX135W

2. SPECIFICATIONS AND DATA

2.1 SPECIFICATIONS AND DATA

This machine is equipped with a 24 Volt electrical system with negative ground. Here below, the electrical
specifications of the components equipping the machine are listed:

• BATTERY
Two batteries, connected in series, equip this machine. Each single battery has the following specifications:
- Nominal voltage ............................................................................................................................. 12 Volt
- Nominal capacity of battery .................................................................................................... 100 Amp h
- Discharge current ...................................................................................................................... 440 Amp
- Weight with electrolyte ..................................................................................................................... 23 kg

• STARTER MOTOR (with safety relay)

- Voltage .......................................................................................................................................... 24 Volt

• ALTERNATOR (with built-in regulator)

- Nominal voltage ............................................................................................................................ 24 Volt
- Nominal current ........................................................................................................................... 50 Amp

• BOOM MOUNTED LIGHT (halogen light)

- Voltage and power ......................................................................................................... 24 Volt, 70/75 W

• FRONT ROAD LIGHT (halogen light)

- Voltage and power .................................................................................. 24 Volt, 5 W - 24 Volt, 70/75 W

• REAR ROAD LIGHT

- Voltage and power .............................................................................................................. 24 Volt, 10 W

• FRONT/REAR TURNING LIGHTS

- Voltage and power .............................................................................................................. 24 Volt, 21 W

• SIDE TURNING LIGHTS

- Voltage and power ................................................................................................................ 24 Volt, 5 W

• WINDSHIELD WIPER MOTOR

- Nominal voltage and current ............................................................................................. 24 Volt, 2 Amp

• CAB LIGHT
- Voltage and power ................................................................................................................ 24 Volt, 5 W

• RADIO
- Voltage .......................................................................................................................................... 24 Volt

• LOUD SPEAKER
- Input power (nominal) ...................................................................................................................... 10 W
- Input power (max.) ........................................................................................................................... 20 W
-Nominal impedance .......................................................................................................................... 4 ohm
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ES8-2-2

SPECIFICATIONS AND DATA EX135W

NOTES:

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ES8-3-1

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

3. LOCATION AND FUNCTIONS OF COMPONENTS

3.1 CONSTRUCTION

The electrical system is 24 Volt with grounded negative. The power is provided by two 12 Volt batteries,
connected in series, kept to the right charge by an alternator with built-in voltage regulator. The alternator is
driven, through a toothed belt, by the pulley on the engine. A fundamental characteristic of this system is that
it is divided into 15 lines connected to a switching control unit located under the operator’s seat Fig. 1 (3),
equipped with a fuse board (2) and a check board (5).

3.2 LOCATION OF ELECTRICAL COMPONENTS

3.2.1 MAIN PARTS LIST

1 - Control lever switch connector P6

2 - Pressure switch connector (reverse travel) P4
3 - Pressure switch connector (forward travel) P5
4 - Fuel sensor
5 - Connector for solenoid valve unit (add to all terminals)
6 - Hydraulic oil level switch
7 - Kick down pressure switch P3
8 - Brake pressure transducer PT
9 - Brake pressure switch 5 bar P2
10 - EC motor
11 - Brake pressure switch 90 bar P1
12 - Working brake solenoid valve D1
13- Engine oil pressure switch P7
14 - Engine oil level L3
15 - Alternator
16 - Engine water thermal switch S2
17 - Max. water temperature thermostat
18 - Battery disconnection switch
19 - Engine water themperature sensor S1
20 - Battery
21 - Starter relay
22 - Windshield washer tank
23 - Air filter clogging sensor S3
24 - Battery disconnection relay
25 - Positioner solenoid valves
26 - Blade-stabilizer solenoid valves
27 - Bucket swing solenoid valves
28 - Link Fuse
60406991
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Note: To consult the general electrical system, refer to the diagram enclosed at the end of this Manual.
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ES8-3-2

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

25
26
24

14

2 3
1 7-8
27

21

13 30
12 17
15 6 18
5 20
11 19
31

4
23
16

28
29
29

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21599
F7111

32
10
9
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ES8-3-3

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

3.2.2 ELECTRICAL COMPONENTS ON TRANSMISSION

Fig. 1

4
5
6

F6976

1 - Gear position sensor (speed shifting)

2 - Cardan speed sensor
3 - Mechanical gearbox solenoid valve
4 - Clutch solenoid valve
60406991

5 - Parking brake solenoid valve

6 - Pressure switch
7 - Solenoid valve
21599
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ES8-3-4

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

3.2.3 ELECTRICAL SYSTEM (RELAYS - DIODES - CONTROL UNITS)

Fig. 2

33
34 30 31
35 29
36
37

RV1 RV8 RV15 RV22

RV2 RV9 RV16 RV23

RV3 RV10 RV17 RV24

RV4 RV11 RV18 RV25

RV5 RV12 RV19 RV26

38
32 RV6 RV13 RV20 RV27

39 A RV7 B RV14 C RV21 D RV28

40
F6977

RY1 - Alternator relay RY21 - Cab light relay (opt.)

RY2 - Safety relay RY22 - F switch relay
RY3 - Anti load dump relay RY23 - E switch relay
RY4 - Working brake light relay RY24 - Upper beam relay
RY5 - Parking brake relay RY25 - Lower beam relay
RY6 - Boom light relay RY26 - Parking light relay
RY7 - Horn relay RY27 - K switch relay
RY8 - Rotating beacon relay RY28 - Parking brake relay
RY9 - Safe start-up relay 29 - Windshield wiper motor
RY10 - Speed light relay 30 - Control panel
RY11 - Servocontrol relay 31 - Wiper Box
RY12 - OPT relay 32 - Air conditioner relay (opt.)
RY13 - Switch relay A 33 - Buzzer diode
RY14 - Switch relay B 34 - Timer
60406991

RY15 - Switch relay C 35 - Diode 3

RY16 - Auto/idle relay 36 - Diode 2
RY17 - Engine stop relay 37 - Diode 1
21599

RY18 - Blade shift relay 38 - APC control unit

RY19 - Relay for right direction indicator 39 - Controller
RY20 - Relay for left direction indicator 40 - SMC control unit
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ES8-3-5

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

3.2.4 ROAD LIGHTS AND WORK LIGHTS

Fig. 3

12

7
6
5
1
3
2
4
2
1
7
6

8
10

9
11
F6978
60406991

1 - Front turning light 7 - Side direction indicator bulb

2 - Front light 8 - Rear reflector
3 - Parking light bulb 9 - Rear light
21599

4 - Low beam bulb 10 - Rear direction indicator bulb

5 - Front direction indicator bulb 11 - Stop/tail light
6 - Side direction indicator 12 - Work light
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ES8-3-6

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

3.3 INSTRUMENTS AND CONTROLS

3.3.1 GENERALITIES

To operate the machine under totally safe conditions, the operator must be perfectly aware both of the
efficiency conditions and the operational capabilities of the unit. To alert promptly the operator, in case of a
problem, several instruments and control devices have been placed on the central dashboard (Fig. 1) and side
dashboard (Fig. 2) together with electrical controls. Electrical control devices are also mounted on the pilot
valves (Fig. 3).
In order to make the descriptions relative to the subjects involved in this chapter, as clear and immediate as
possible, references are made to the electrical system diagram.

Fig. 1 - Central dash-board

3
4
TB 1 2
EX

4
4
10 30
Km/h

1
2

15 20
10 25
P
5 Km/h
30
0
F6979
60406991
21599

1 - Brake commutator, axle lock

2 - Pannello interruttori e spie 3
3 - Interruttori e spie
4 - Interruttori sulle leve al volante
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ES8-3-7

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Fig. 2 - Side dashboard

1
2

3
4
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21599

1 - Control module
2 - Switches and indicators panel
F7123
3 - Engine starter switch
4 - Hand throttle control
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ES8-3-8

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Fig. 3 - Pilot valves

1 2

F6980

1 - Button switches on left pilot valve

2 - Button switches on right pilot valve.
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ES8-3-9

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Switches and indicators panel 3

Fig. 5

TB 1 2
EX

10 30
Km/h

15 20
10 25
P 4
5 Km/h
30
3
0
F6981
1

1 - Work brake indicator

The actuation of this indicator shows that the work brake is applied.

2 - Work brake switch

When this switch is actuated, the work brake is effective.
Parking brake switch
When this switch is actuated, the service brake is ON.
With the electrical panel under voltage the parking brake is released when turning the switch.
Axle lock switch
When this switch is actuated, the front axle is locked in the position it has at the moment.

3 - Parking brake indicator

The actuation of this indicator shows that the parking brake is applied.

4 - Axle lock indicator

60406991

The actuation of this indicator shows that the axle lock is applied.
21599
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ES8-3-10

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Switches and indicators

Fig. 5

5
8
8
1
6
2
20
10
25
5 Km/h P
TB
30 1 2
0 EX

10 30
Km/h

15 20
10 25
P
5 Km/h
30 7
0
9
4 F7126

1 - 1st speed indicator

The actuation of this indicator shows that the 1st speed has been selected.

2 - 2nd speed indicator

The actuation of this indicator shows that the 2nd speed has been selected.

3 - Rotary beacon switch

When this switch is actuated, the rotary beacon is ON.

4 - Brake failure indicator

The actuation of this indicator shows that the braking system is malfunctioning.

5 - Positioner arm indicator

The actuation of this indicator shows that the positioner arm control is actuated.

6 - Emergency flashing lights switch

When this switch is actuated, all front and rear direction lights are flashing at the same time, to signal
an emergency situation.
60406991

7 - Side lights
The actuation of this indicator shows that the side/tail lights-low beams are actuated.
21599

8 - Direction lights indicator

The actuation of this indicator shows that the direction indicator or the emergency flashing signal is
actuated.

9 - Low beam indicator

The actuation of this indicator shows that the low beam lights are ON.
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ES8-3-11

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Switches on levers mounted on the steering column

Fig. 6

5
TB
EX
1 2
1
2 3
4
10 30
Km/h

15 20
10 25
P
5 Km/h
30
0
F6982

1 - Direction lights control, lights switch

When moving or rotating this lever, the relevant circuits are actuated, thus providing the powering of
the following equipment:
- right and left direction lights;
- side and tail lights;
- low beam lights;
- high beam lights.

2 - Windshield wiper control lever

When moving this lever or pressing its end, the relevant electrical circuits are actuated, thus providing
the powering of the following equipment:
- windshield wiper;
- windshield washer motor.

3 - Travel speed selection lever

When moving this lever, electric signals are sent to the APC50 control unit, relevant to the following
60406991

travel conditions:
- 1st speed;
- automatic speed;
21599

- 2nd speed.

4 - Horn

5 - Emergency lights switch

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ES8-3-12

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Steering column panel 18 23

27 7
Fig. 7
8 25
1 - Travel mode switch. 24
5
2 - Switch for direction indicators, upper
beams, lower beams and parking lights.

3 - Horn. TB
EX
1 2

2
6
3 1
4 - Brake switch, axle lock.
10 30
Km/h

5 - Hazard lights switch.

6 - Windshield wiper switch. 4

16
7 - Warning light for right turn signal. 10
13
8 - Warning light for left turn signal. 20
10
15
25
11
P
9 - Speed indicator (tachometer). 5 Km/h
30
14
0 15
10 - Warning light for parking lights. 12
17 F6983

11 - Warning light for upper beams. 9

12 - Warning light for low brake pressure

(buzzer).

13 - Warning light for axle lock.

14 - Parking brake warning light.

15 - Warning light for working brake.

16 - Warning light for hazard lights.

17 - Pressure gauge for braking pressure.

15 20
18 - Warning light for rotating beacons. 5
10

Km/h
25
P
30
0

19 - Equipment lock switch.

19
20 - Available switch (hammer/grass-cutter). 21 22
20
21 - Tipping device switch.
26
22 - Rotating beacon switch.
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23 - Warning light for tipping device (yellow).

24 - Warning light for equipment lock.

21599

25 - Travel mode warning lights (1), (2).

26 - Lever for steering adjustment.

F7124
27 - TB/EX warning light.
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ES8-3-13

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

3.3.3 FUNCTIONS OF SIDE DASHBOARD

Control module

Fig. 8

12
H
11
C F
7 E

6 10
2 E
A/I 8
1 3
4 5

CHECK
00 0014 E H
1/10

2
1
OFF

A/I

F6984

1 - Alternator indicator
The actuation of this indicator shows that a failure in the battery recharging system has occurred.

2 - Engine oil pressure indicator

The red indicator comes ON in case of low engine oil pressure.

3 - Air cleaner clogging indicator

The actuation of this indicator shows that the air cleaner is clogged.

4 - Engine coolant temperature indicator

The actuation of this indicator shows that the temperature of the coolant is above the prescribed
value.

5 - Fuel indicator
The actuation of this indicator shows that the fuel level is in reserve conditions.
60406991

6 - Engine oil level indicator

This indicator comes ON when, pressing the check button (1 - Fig. 9) the level is inadequate).
21599

7 - Coolant level indicator

This indicator comes ON when, pressing the check button (1 - Fig. 9) the level is inadequate).

8 - Hydraulic oil level indicator

This indicator comes ON when, pressing the check button (1 - Fig. 9) the level is inadequate).
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ES8-3-14

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

9- Hourmeter
This instrument recording the total hours worked, operates when the engine runs (a LED flashes),
must be used as a guide for the maintenance operations and checks scheduled in chapter 8 of the
“Operation and Maintenance Manual”.

10 - Fuel level gauge

This instruments shows the level of the fuel contained in the reservoir.

11 - Engine coolant temperature gauge

This instrument shows the temperature of the engine coolant.

12 - Machine preheating warning light

Switches and indicators panel 1

Fig. 9

CHECK

2
1
OFF

1
3
A/I

4
2

F6985

1 - Check button
When pushing this button, it is possible to test, through the actuation of the indicators (6, 7, 8) the
following levels:
- engine oil;
- coolant;
- hydraulic motor oil.

2 - Alarm buzzer cut-off switch

When this switch is actuated, the engine coolant excessive temperature and low engine oil pressure
sound alarm is neutralised (actuation of indicators 7 and 2) . In this case, it is required that the alarm
is disactivated, bring the engine to idle speed and keep it running for a few minutes at this speed. To
60406991

test the operation of the alarm, push this switch when the engine is running.

3 - Work light switch

21599

When this switch is actuated, the work light comes ON.

4 - Button A/1 (Auto idle)

If pressing button (4) indicator (yellow) on control panel comes ON. Press the button again to disconnect
auto-idle function. At the same time the corresponding indicator comes OFF.
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ES8-3-15

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Starter switch

Fig. 10

F6986

1 - Starter switch
The starter switch has four positions, each actuating the electrical system in the following manner:
- position OFF, no power to the system;
- position ACC, all equipment powered, except starter circuit;
- position ON, all equipment powered after the starting of the engine;
- position START, engine starting circuit is powered (unstable position).

Note: When moving the starter key into position “ON”, all the indicators on the control module come
ON (test of bulbs) for about 3 seconds, except for the following indicators:
• insufficient battery charging;
• insufficient engine oil pressure;
that will remain ON until the engine is started.
If one of the indicators is not ON during the test function, the relevant bulb could be burnt out.
60406991
19400
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ES8-3-16

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Left manual pilot valve

Fig. 11

B G
A C

F7125

A - Button
When this switch button is actuated, solenoid valves A3 - B1 - B2 are energised, allowing the hydraulic
system to feed pressurised oil to the blade line.

B - Button
When this switch button is actuated, solenoid valves B1 - B2 are energised, allowing the
hydraulic system to feed pressurised oil to the left stabiliser line.

C - Button
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When this switch button is actuated, solenoid valves B1 - B2 - A4 are energised, allowing
the hydraulic system to feed pressurised oil to the right stabiliser line.
21599

G - Horn control button

When this switch button is actuated, the horn is activated.
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ES8-3-17

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Right manual pilot valve

Fig. 12

K
F
E
D

20

F6987

D - Button
When this switch button is actuated, solenoid valves B3 - B4 are energised, allowing the hydraulic
system to feed pressurised oil to the positioner arm line, TB/EX version.

E - Button
When this switch button is actuated, solenoid valve C1 is energised, allowing the hydraulic system to
feed pressurised oil to the clam bucket to rotate it leftward.

F - Button
60406991

When this switch button is actuated, solenoid valve C2 is energised, allowing the hydraulic system to
feed pressurised oil to the clam bucket to rotate it rightward.
21599

K - Button, optional control

When this switch button is actuated, solenoid valve A5 is energised, allowing the hydraulic system to
feed pressurised oil to the hammer or grass-cutter, by means of switch (20) the solenoid valve A6 is
fed.
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ES8-3-18

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

ELECTRICAL SYSTEM (monitor and switch panels)

Fig. 13

10
24
H
C F 11
E
22 12
21 13
E
19 A/I 14
18 15
1
17
2

CHECK

16
20
6

4 25
9 5 CHECK

2
23 1
OFF
7
8
26
A/I

28
27

F6988

1 - Monitor panel 17 - Fuel level indicator

2 - Switch panel 18 - Overheat indicator
4 - Key switch 19 - Low battery charge indicator
5 - Cigar lighter 20 - Engine oil pressure indicator
6 - Work light indicator 21 - Engine oil level indicator
7 - E mode switch 22 - Coolant level indicator
8 - Engine control dial 23 - Level check indicator
60406991

9 - Air conditioner panel (if installed) 24 - Coolant temperature gauge

10 - Wam up complete indicator 25 - Work light switch
21599

11 - Fuel gauge 26 - Travel mode switch

12 - E mode indicator 27 - Buzzer stop switch
13 - Auto-idle indicator 28 - Auto-idle switch
14 - Hydraulic oil level indicator
15 - Air heater (preheat) indicator
16 - Air filter restriction indicator
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ES8-3-19

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Fuse Rating
PROTECTED CIRCUIT
No. (AMP)
FUSES IN THE BOX

1 Function memory 5
2 Engine control 10
3 Step-by-step motor 10
4 Power supply 5
5 Pump control solenoid 5
6 Switch panel 5
7 OPT
8 OPT
9 Bucket rot. & overturn sensor 5
10 Cab lights (opt) 10
11 Upper lights (opt) 20
12 Wind screen wiper 10
20 19 18 17 16 15 14 13 12 11
13 Heater 20
14 OPT
15 Horn 5 10 9 8 7 6 5 4 3 2 1

16 Radio 5
17 Cigarette-lighter 10
18 Ceiling light 5
40 39 38 37 36 35 34 33 32 31
19 Air conditioner (opt) 10
20 OPT
21 R.H. parking light 5 30 29 28 27 26 25 24 23 22 21
22 L.H. parking light + ceiling light 5
F5666

23 Traffic beams 10
Upper beams
24 10
(not used for homologation)
25 Case (1) 20
26 Stop lights 5
27 OPT
28 Steering column panel 5
29 Boom lights 5
60406991

30 Rotating beacon 5
19400

31 Gearbox card 10
32 L.H. knob 10
33 Case (2) 5
34 Socket 10
F5684gb
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ES8-3-20

LOCATION AND FUNCTIONS OF COMPONENTS EX135W

Fuse Rating
PROTECTED CIRCUIT
No. (AMP)
FUSES IN THE BOX
35 Solenoid C2 5
36 Emergency lights 10
37 Positioner valve 5
38 Heated sat 10
39 OPT
40 OPT
CENTRAL UNIT FUSES
FUSE FUSE FUSE FUSE

F5663
Main power supply with key 40
1
BOX A

Engine start-up line

80
3
BOX B

protection

Engine shut-down protection 40 FUSE 3 FUSE 1

4

F5683gb

FUSE 4 FUSE 2
F5667
60406991
19400
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ES8-4-1

ARRANGEMENT AND OPERATION EX135W

4. ARRANGEMENTS AND OPERATION

4.1 ELECTRICAL SYSTEM

4.1.1 DESCRIPTION

This chapter will deal with the Switching Control Unit and the 15 Lines that make the electrical system, as
previously described. The information will be provided always referring to the electrical system. Thus, it will
be imperative, prior to reading this chapter, unfold the electrical system diagram and keep it handy, so that
it can be easily accessible.

4.1.2 OUTLINE

The electrical system is classified into the main circuit, control circuit and monitor circuit.
• Main circuit operates the engine and accessories.
• Control circuit functions to control operations of the engine, hydraulic pumps and valves (including actuators
such as solenoid valves, SMC (Main Controller), switch box, sensors and pressure switches).
• Monitor circuit operates the monitor devices consisting of the monitors, sensors and switches.
In this group the functions and constructions of the main circuit are introduced.
• Electric power circuit:
Supplies electric power to all electric system on this machine. (Key switch, batteries, fuses (fuse box and fuse
40A), battery relay)
• Circuit in position (ON). It operates key switch, battery relay, fuses and monitor.
• Starting circuit: starts the engine. (Key switch, starter, starter relay).
• Charging circuit: recharges battery and supplies consumption electricity. (Alternator, regulator).
• Surge voltage prevention circuit: prevents surge voltage from occurring when the engine is stopped. (Anti
load dump relay).
• Bulb check accessory circuit: works with the key switch placed in the ACC position (key switch, battery,
fuses).
• Engine stop circuit: when the key switch is placed in OFF position, stops the engine with the solenoid
(Synchro-start).

4.1.3 ELECTRIC POWER CIRCUIT (Key switch: OFF)

The battery negative terminal is grounded to the vehicle. Current from the positive terminal flows as follows
with the key switch OFF.
Battery Fuse 40A Key switch B
Anti load dump relay (R3)
Safety relay (R2)
Fuse box
Terminal 1 - Backup power source/digital clock and memory
Terminal 2 - SMC (power source)
Terminal 3 - MC (EC motor)
Terminal 5 - Controller Box
Terminal 5C - Dashboard for steering column and emergency
lights column
Terminal 19 - Air conditioner
60406991
21599

Note: To consult the general electrical system, refer to the diagram enclosed at the end of this Manual.
 H
OFF Key switch
ACC
Steering column
Electrical pump for ON
fuel transfer START

Battery
Fuse box
Safety relay R2

Relay R3

Backup supply
ARRANGEMENT AND OPERATION EX135W

Battery

Air conditioner
Controller
Box Terminal 5
Clock- Radio Memory
Fuse 40 Amp

SMC
EC motor
ES8-4-2

F6989

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ARRANGEMENT AND OPERATION EX135W

4.1.4 BULB CHECK ACCESSORY CIRCUIT (Key switch: ACC)

When the key switch is turned to the ACC position, terminal ACC is connected to terminal B in the key switch.
Then, the battery current flows through the fuse box to each accessory circuit such as the horn, radio, cigar
lighter, room lamp.

H
OFF Key switch
ACC
ON
START
Electrical pump for fuel
transfer

Battery

Fuse 40 Amp

Battery
Cigar-lighter

Ceiling light
Radio
Horn

F6990
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ARRANGEMENT AND OPERATION EX135W

4.1.5 CIRCUIT IN THE ON POSITION

When the key switch is turned to the ON position, key switch terminal B connects with key switch terminals
M and ACC.
The current from terminal M excites the battery relay. Then, the battery power is routed to the monitor through
the battery relay and the fuse box.
At the same time, the battery power via the fuse box is supplied as power source to the work lights, wiper,
heater, intake air heater controller (terminal 15), SMC (solenoid valve power source) and optional circuits.

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ES8-4-5

ARRANGEMENT AND OPERATION EX135W

Battery

Electrical pump for fuel transfer Key switch

Steer. column pan.

Rotat. beacon
Upper lights
Stop lights

Arm light
Fuse 40 Amp

Socket

Cab light
Battery Diode

Radio
D6

Lights
Tipp. buck. swing

Windshield wiper

Horn
Left control lever

Pump check sol.

Battery relay
Gearbox card

Switch panel

Anti load dump

Cab lights

Fuse 80 Amp
relay R3
Heater

Box 2

Main SMC

Alternator

Controller box

F7027
Engine stop coil relay
60406991

Electrostop
21599
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ES8-4-6

ARRANGEMENT AND OPERATION EX135W

4.1.6 STARTING CIRCUIT (Key switch: START)

When the key switch is turned to the START position, terminal B on the key switch is connected to terminals
G2, M and ST in the switch. The current from terminal M magnetizes the battery relay, leading the battery
current to terminals B on the starter and starter relay via the 80A fuse.
Terminal ST of the key switch is connected to terminal “e” on the starter relay so that the battery current flows
through the coil and actuate the starter relay via the closed contact of safety relay (R2).
The starter relay, closing the contacts, allows the battery current to flow toward the terminal C on the starter
and actuate the inner starter relay. Thereby, the starter begins to rotate.
At the same time, when the key switch is turned both ON and START positions, from terminal M, the power
supply is applied, via POWER ON fuse (4), to main controller (SMC) and to engine stop relay (R17). This power
on signal instructs the main controller the key switch is in ON position. The main controller, when receives the
power on signal, operates the EC motor in order to move the governor lever.
Further, with key switch in START position, the voltage from fuse 40A, is routed to the terminal B of solenoid
relay related to push coil of high power to actuate the solenoid (Synchro-start).
The solenoid relay is actuated through the timer control and is maintained actuated for about 1 second, after
that the timer inhibits the excitation of solenoid relay in order to avoid failure the push coil of solenoid (Synchro-
start). Turning again the key switch to OFF, after about 3 to 5 seconds, the starting can be repeated.
The voltage from terminal M of key switch, is led, through POWER ON fuse and engine stop relay (R17) in
de-energized condition, to the terminal C related to holding coil of the solenoid (Synchro-start).
With solenoid (Synchro-start) poweredin both coils (push (B) (1 sec. max) and holding (C)) the solenoid is
actuated and the fuel flow is opened to injection pump.
With engine running and alternator generating voltage, the terminal C-2 of monitor operates the safety relay
(R2) that removes the ground to starter relay, shutting-off the power supply to the starter.
Moreover the safety relay (R2) avoids a further starting sequence with engine running.
With safety relay (R2) excited, the ground is also disconnected from the solenoid relay. Therefore, with the
solenoid relay de-energized, the power supply to the push coil (B) of solenoid (Synchro-start) is removed.

60406991
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 19400 60406991

Electrical pump
for fuel transfer
Key switch
H
OFF
ACC
ON
START

Fuse 5 Amp
Battery Fuse 40 Amp

Diode D1

Battery

Battery relay Control

panel
Relay R5
Fuse 80Amp
Safety relay

Stop relay

Starter Engine stop

ARRANGEMENT AND OPERATION EX135W

Solenoid relay solenoid starter

Start-up relay

Main SMC
Diode D4
Diode D2
Diode D5
Solenoid
F7028
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ES8-4-8

ARRANGEMENT AND OPERATION EX135W

4.1.7 CHARGING CIRCUIT (Key switch: ON)

After the engine starts and the key switch is released, the key switch is returned to the ON position. With the
key switch kept ON, key switch terminal B is connected to terminals ACC and M.
After the engine starts, the alternator begins to recharge the batteries. Current from terminal B on the
alternator flows to the batteries through the fuse 80A and the battery relay, recharging the batteries.
In addition, this current is supplied through the fuse box as a power source to the solenoid valves, switch box,
hour meter, work lights, wiper and heater. At the same time, the current from alternator B+ flows to the
alternator relay (R1) to turn off the alternator indicator light (battery charging) on monitor and to main controller
(SMC) for alternator power on signal.

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 21599 60406991

Battery

OFF
ACC
ON
Key switch
START
Battery Electrical pump for
fuel transfer

Fuse box

Diode D1

Battery relay

Fuse 80 Amp
ARRANGEMENT AND OPERATION EX135W

Alternator relay R1

Control panel
Alternator

F7029
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ES8-4-10

ARRANGEMENT AND OPERATION EX135W

4.1.8 SURGE VOLTAGE PREVENTION CIRCUIT

The surge voltage prevention circuit protect the electrical parts and components in the controller from being
damaged by the alternator generating surge current developed when the engine is stopped. While the
batteries are being recharged, the generating current from terminal D+ on the alternator is led, via alternator
relay (R1), to terminal C-14 on the monitor, turning off warning light and setting transistor for terminal B-6 on
a negative that energizes, and then operates, anti load dump relay (R3).
Thereby, the battery current is supplied to the magnetizing circuit for the anti load dump relay (R3) to close
it. Accordingly, even if the key switch is turned OFF while the engine is running, the battery current supplied
through the anti load dump relay (R3) magnetizes the battery relay OFF until the alternator stops generating.

60406991
21599
 21599 60406991

H Key switch
OFF
ACC
ON
Battery START
Electrical pump for fuel transfer

Battery Diode D1
Anti load dump

relay R3

Battery relay

Fuse 80 Amp
ARRANGEMENT AND OPERATION EX135W

Alternator relay
C-14
B-6

Control panel
Alternator
F7030
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ES8-4-12

ARRANGEMENT AND OPERATION EX135W

4.1.9 ENGINE STOP CIRCUIT

When the key switch is turned from the ON position to the OFF position, the signal instructing the SMC that
the key switch is ON is cut off.
Then, the SMC moves the EC motor to the slow idle position. At the same time, the synchro-start solenoid
(terminal C related to the holding coil) located on the injection pump is de-energized causing the engineto
stop for lack of fuel supply.

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 19400 60406991

H
OFF Key switch
ACC
Battery ON
START

Electrical pump for

fuel transfer

Fuse
Battery
Fuse box
Diode D1
ON

Anti load dump

relay R3
Power Signal

Fuse
Battery relay
40 Amp Main SMC

Fuse 80 Amp
Solenoid relay
ARRANGEMENT AND OPERATION EX135W

Coil relay for

engine stop
Engine stop
Alternator R17
Diode D4 solenoid timer

Diode D5 Diode D2
Electrostop syncro Control panel
F7031
start
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ES8-4-14

ARRANGEMENT AND OPERATION EX135W

4.1.10 ENGINE CONTROL

The engine control system has the following control functions:

• Normal control
• E mode control
• Auto-idle control
• Travel motor speed change control

Layout of engine control system

P6

P4 P5

Key switch

EC sensor
Engine control
dial ENGINE
M
Auto-idle switch
SMC
A/I
EC motor

F7032
E mode switch
E

P4 Reverse pressure switch

P5 Positioner forward pressure switch
60406991

P6 Auto idle pressure switch

21599
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ES8-4-15

ARRANGEMENT AND OPERATION EX135W

Normal control

Purpose: to control engine speed in response to the operation angle of the engine control dial on the switch
panel.
Operation: in response to the operation angle of the engine control dial, the (SMC) drives the EC motor,
causing the governor lever to move to control engine speed.

P6

P4 P5
P/V

Key switch

EC sensor
Engine control
dial ENGINE

M
Auto-idle switch
SMC
A/I
EC motor

F7032
E mode switch
E
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ES8-4-16

ARRANGEMENT AND OPERATION EX135W

E mode control

Purpose: to decrease the engine speed at a fixed rate.

Operation: when the E mode switch is ON, the SMC instructs the EC motor to run the engine in the speed
range slower than normal operation in proportion to the engine control dial set angle.

Engine speed

When the E mode switch is

not depressed

When the E mode

switch is depressed
Slow idle Fast idle
Slow idle Fast idle
F7034

P6

P4 P5
P/V

Key switch

EC sensor
Engine control
dial ENGINE

M
Auto-idle switch
SMC
A/I
EC motor

F7032
E mode switch
60406991

E
21599
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ES8-4-17

ARRANGEMENT AND OPERATION EX135W

Auto-idle control

Purpose: to slow the engine speed when all control levers are in neutral to reduce fuel consumption and noise.
Operation: when the auto-idle switch is ON and all control levers are kept in neutral for more than four
seconds, the SMC instructs the EC motor to reduce the engine speed to the auto-idle speed.

P6

P4 P5
P/V

Key switch

EC sensor
Engine control
dial ENGINE
M
Auto-idle switch
SMC
A/I
EC motor

F7032
E mode switch
E
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ES8-4-18

ARRANGEMENT AND OPERATION EX135W

Travel motor swash angle control

Purpose: to change fast/slow travel speed.

Operation: when the travel mode switch is in slow position, magnetizes solenoid valve (A3) allowing pilot oil
pressure to change the travel motor swash angle control valve port. The travel motor swash angle is held at
a large angle, causing the machine to travel at a slow speed.
When the travel mode switch is in fast position, the travel motor swash angle is reduced to cause the machine
to travel at a fast speed.

+
R9

R18

R13

Slow/fast
A3 speed
switch

F7037
60406991
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ES8-5-1

ELECTRONIC UNITS EX135W

5. ELECTRONIC CONTROL UNITS AND DIODES

5.1 GENERALITIES

The systems of this group identify the connections coming and leaving the groups for an esier troubleshooting.
They also identify all the wire as numbered on the machines.

F7040
60406991

Wire colour
W = White
21599

R = Red
Br = Brown
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ES8-5-2

ELECTRONIC UNITS EX135W

CONNECTIONS WITH DIODES

F7039
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ELECTRONIC UNITS EX135W

5.1.1 CONNECTIONS WITH FUSE BOX

F11155
60406991

Wire colour
19400

W = White
R = Red
Br = Brown
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH FUSE BOX

60406991
21599

F7314
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH FUSE BOX

F7041
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ELECTRONIC UNITS EX135W

5.1.2 CONNECTIONS WITH MINI RELAYS

F7044
60406991

Wire colour
W = White
21599

R = Red
Br = Brown
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH MINI RELAYS

60406991
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F7315
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH MINI RELAYS

60406991
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F7316
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH MINI RELAYS

60406991
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F7317
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ES8-5-10

ELECTRONIC UNITS EX135W

CONNECTIONS WITH MINI RELAYS

F7043

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ELECTRONIC UNITS EX135W

5.2 APC50 ELECTRONIC UNIT

5.2.1 GENERALITIES

The APC50 unit, located on the right side dashboard, complete with the control display, is providing
automatically (through the micro processor), the operation of the transmission.
The APC50 microprocessor controls, in real time, the gearshifting sequence as a function of the r.p.m. and
the speed gear engaged.
With the gearshift lever in central position (automatic):
• if the speed measured is increasing (about 330 r.p.m. max. threshold) the microprocessor provides the logic
signals to arrange the gearshifting sequence from 1st fi 2nd;
• if the speed measured is decreasing (about 80 r.p.m. min. threshold), the microprocessor provides the logic
signals to arrange the gearshifting sequence from 2nd fi 1st.
The APC50 microprocessor (changing the above mentioned thresholds) manages the kick-down function,
thus allowing the machine to improve the travel performance in busy traffic conditions or during up-hill travels.
It is capable, also, of diagnosing, in real time, the operation of the transmission.

3 4

1 - Display
2 - Multifunction button
3 - Indicator, transmission control (yellow)
4 - Indicator, unit failure (red)
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Note: To consult the general electrical system, refer to the diagram enclosed at the end of this Manual.
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ELECTRONIC UNITS EX135W

Electrical connections of APC50 unit with the general electrical system

For the electrical connections of the APC50 control unit, refer to the general electrical system.

F7128

Wire colour
W = White
R = Red
Br = Brown

F7045

5.2.2 DISPLAY
60406991

The visualisation of the display is of a digital type with seven light segments. This visualisation changes as
a function of the control selected (through the multi function button) as follows:
Note - As soon as power is provided to the machine, the display visualises the real position of the transmission
21599

gears and eventual error codes.

1st multi function button selection ⇒ the display visualises the speed of the prop shaft, expressed in
r.p.m.
2nd multi function button selection ⇒ the display visualises the speed of the machine, expressed in km/h.
3rd multi function button selection ⇒ the display visualises the input of the control signals.
4th multi function button selection ⇒ to return to the first selection on the display.
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ELECTRONIC UNITS EX135W

Real position of the transmission gears and error codes

In the right segment, the display visualises the real position of the gears of the transmission.
If the gear shifting lever is in a position not corresponding to the real position of the gears of the transmission,
and the gear shifting is impossible, the display will visualise on the left segment (fixed light) the speed
requested and on the right segment (flashing light) the gear position really engaged.

Transmission in first gear Transmission in second gear

In case an error is occurring during the logic sequence of the transmission control, the display visualises a
message (E) followed by the relevant error code (1. - 2 - 3 - 4 - 5 - 6 - 7 - 8).

Visualisation of error code

E 1. ⇒ movement of gear shifting cylinder during the closing phase of the clutch.
E 2 ⇒ clutch remained open.
E 3 ⇒ clutch remained closed.
E 4 ⇒ gear shifting cylinder does not move.
E 5 ⇒ gear shifting cylinder moves, but it does not select the speed chosen.
E 6 ⇒ movement of the gear shifting cylinder is monitored during the initial phase of the shifting.
E 7 ⇒ movement of the shifting cylinder too fast.
E 8 ⇒ movement of the shifting cylinder during the opening phase of the clutch.

Speed of the prop shaft

The display indicates the revolving speed of the prop shaft, shown in r.p.m..
If the display does not indicate any point, such a value must be multiplied by 10, to obtain the real value of
the rotation.
If the display visualises a point on the side of the first digit, this value must be multiplied by 100, to obtain the
real value of the rotation.
60406991

250 r.p.m. 1200 r.p.m.

21599
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ES8-5-14

ELECTRONIC UNITS EX135W

Speed of the machine

The display shows the speed of the machine, in km per hour. The figure indicating the speed will be
accompanied by the showing of a point.

7 km/h 12 km/h

Control of the input signals

The control of the input signals occurs in the following manner:

Move the gearshift lever into automatic mode.

The display should show the segment, as illustrated.

Move the gearshift lever into second speed.

The display should show the segment, as illustrated.

Disengage the parking brake.

The display should show the segment, as illustrated.

Press the forward travel pedal.

The display should show the segment, as illustrated.
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ELECTRONIC UNITS EX135W

Press the reverse travel pedal.

The display should show the segment, as illustrated.

Start the machine, then move the gearshift lever from 1st ⇒ 2nd
or from 2nd ⇒ 1st speed.
The display should show the segment, as illustrated.

Select the “Rabbit” function, then press the forward travel pedal.
The display should show the segment, as illustrated.

5.2.3 PRINTING OF THE MEMORISED INFORMATION

The APC50 unit can be connected (through a serial connection) to an appropriate printer capable of providing
all the data, memorised by the unit itself, relative to various operating conditions performed.

These data can be summarised as follows:

• how long the machine has been operated;
• the quantity of gear shifting from 1st ⇒ 2nd or from 2nd ⇒ 1st made with the machine standing;
• the quantity of gear shifting from 1st ⇒ 2nd or from 2nd ⇒ 1st made with the pedal pilot valve no more than
1/2 way of its stroke;
• the quantity of gear shifting from 1st ⇒ 2nd or from 2nd ⇒ 1st made with the pedal pilot valve at full stroke;
• the times the APC50 unit has been disconnected, for whatever reason.

Note: Germany version

The display will show the illustrated segment.

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ELECTRONIC UNITS EX135W

5.3 ELECTRONIC UNIT

5.3.1 GENERALITIES

The electronic unit, located under the heater control, has the purpose of checking (with the starter switch key
in the first position) the efficiency of mini relays.

Wire colour
W = White
R = Red
Br = Brown F7055

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F7054
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ELECTRONIC UNITS EX135W

5.3.2 CONNECTIONS WITH WINDSHIELD WIPER CONTROL UNIT AND SWITCH/INDICATOR PANEL

F7127
60406991

Wire colour
W = White
21599

R = Red
Br = Brown
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH WINDSHIELD WIPER CHECK CONTROL UNIT AND SWITCHES-INDICATORS

PANEL

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21599

F7046
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ELECTRONIC UNITS EX135W

5.3.3 CONNECTION BETWEEN CAB AND OPERATORS SEAT

ENG ./ H

ENG ./ H

ENG ./ H

ENG ./ H

F7129
60406991

Wire colour
W = White
21599

R = Red
Br = Brown
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ES8-5-20

ELECTRONIC UNITS EX135W

CONNECTIONS WITH ROTATING JOINT

60406991
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F7318
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH ROTATING JOINT

F7047
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ELECTRONIC UNITS EX135W

5.3.4 CONNECTIONS WITH STEERING COLUMN

F7130

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ELECTRONIC UNITS EX135W

CONNECTIONS WITH STEERING COLUMN

60406991
21599

F7319
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ELECTRONIC UNITS EX135W

CONNECTIONS WITH STEERING COLUMN

F7048

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ELECTRONIC UNITS EX135W

5.3.5 CONNECTIONS WITH OPERATOR'S RIGHT SIDE

F7131
60406991

Wire colour
W = White
21599

R = Red
Br = Brown
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ES8-5-26

ELECTRONIC UNITS EX135W

CONNECTIONS WITH OPERATOR'S RIGHT SIDE

F7049

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ES8-5-27

ELECTRONIC UNITS EX135W

5.3.6 CONNECTIONS WITH OPERATOR'S LEFT SIDE

LEFT MANIPOLATOR

RADIO

SWITCH SOTTO BRACCIOLO

WITCH UNDER LEFT MANIP.
F7132
60406991

Wire colour
W = White
21599

R = Red
Br = Brown
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ES8-5-28

ELECTRONIC UNITS EX135W

CONNECTIONS WITH OPERATOR'S LEFT SIDE

F7050

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ES8-5-29

ELECTRONIC UNITS EX135W

5.4 THROTTLE PISTON CONTROL ELECTRONIC UNIT

5.4.1 GENERALITIES

The electronic unit, located into radiator compartment, is providing the control of the throttle control piston.
The variation of the engine speed, can occur in a pre-arranged mode or manually. In both cases, the unit
controls the piston, that will position the lever located on the injection pump, at an angle corresponding to the
desired engine speed.

F7133
60406991
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ES8-5-30

ELECTRONIC UNITS EX135W

CONNECTIONS WITH ELECTRONIC UNIT SMC

60406991
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F7051
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ES8-5-31

ELECTRONIC UNITS EX135W

5.4.2 CONNECTIONS WITH CAB

F7134

Wire colour
W = White
R = Red
Br = Brown
60406991
21599

F7052
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ES8-5-32

ELECTRONIC UNITS EX135W

5.4.3 CONNECTIONS WITH TEST CONNECTIONS

Programmation switch

F7135

Wire colour
W = White
R = Red
Br = Brown 60406991
21599

F7053
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ES8-6-1

ELECTRIC COMPONENTS EX135W

6. ELECTRIC COMPONENTS

6.1 THROTTLE CONTROL

The throttle control is operated by an EC motor and swing is controlled by the sensore located on the metal
housing next to EC motor rotor. EC motor (1) has no possibility of being disassembled, since its components
(housing, electric motor, mobile rod, cap) cannot be maintained.

F7056

EC MOTOR

The EC motor is used to adjust engine speed.

It includes a worm screw coupled to a helical wheel to avoid synchronism loss.
On the outlet gear is fitted an angle sensor measuring EC motor swing degrees to calculate the position of
injection pump control.

Outlet shaft Worm screw

Outlet gear
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21599

Sensor gear
Motor

Angle sensor F7497

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ES8-6-2

ELECTRIC COMPONENTS EX135W

6.2 CENTER JOINT

6.2.1 GENERALITIES

The center joint, allows the passage of hydraulic oil and the electrical wiring between the turret (swinging part)
and the undercarriage (fixed part).
The description here below analyses the electrical collector only.
This collector is made of a ten ring pack (1), separated by insulating diaphragms and brushes (2) equipped
with connectors for the input and output wires.
The ring pack is secured to the inner part of the support, whereas the brush holder groups are connected to
the structure of the collector itself, that in turn, is secured to the outer part of the center joint.
The particular structure of protection cover (3), opening upward, allows the wiring, inspection and maintenance
operations.

6.2.2 MAINTENANCE

In order to obtain a correct wiring, it is necessary to follow the follow cautions:

• check that, internally, there are no eventual deposits of graphite powder; in such a case, remove them using
a dry rag;
Warning - Never use water or other liquids. The rings must always be dry and clean.
• ensure that the contact between wire and brush holder is perfect;
• check that the input and output wires are correctly secured, so that any interference of the wires with moving
parts is avoided;
• check that all brushes are perfectly placed in their seat and aligned in the groove of the corresponding ring;
• check the correct tightening of all electrical and hydraulic connections.

WARNING - Always disconnect the electric power prior to the removal of the protecting cover and ensure that
it cannot be returned during the maintenance operations.

2 1 60406991
21599

1 - Rings pack
2 - Brush holder group
3 - Protecting cover
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ES8-6-3

ELECTRIC COMPONENTS EX135W

6.3 BATTERIES

6.3.1 DESCRIPTION

The machine includes two free-maintenance and series-mounted batteries (1). For battery disconnection, set
the relative switch (2) to position OFF.

6.3.2 ELECTRICAL FEATURES

Nominal voltage 12V

Nominal capacity (20 h) 100 Ah

Discharge current (-18°C) 440 A

6.3.3 MAINTENANCE PRECAUTIONS

• Make sure the two batteries are correctly connected.

• Batteries contain SULPHURIC ACID:
Always protect your eyes when working near batteries, to avoid accidental contact with the acid solution.
In case the solution comes in contact with your skin or eyes, rinse immediately and call a doctor.
• The gas released by the batteries is highly inflammable:
in case of battery recharge, leave battery compartment open to improve ventilation. Avoid to recharge in
closed rooms. Do not keep sparks or open flames close to batteries.
• Disconnect batteries before any maintenance operation on main machine electrical system.

6.3.4 PROTECTION FUSE

The electrical system includes three fuses Link 40A for battery protection located in the same compartment:
two with 40A and one with 80A.
60406991
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F7004
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ES8-6-4

ELECTRIC COMPONENTS EX135W

6.4 ALTERNATOR

6.4.1 DESCRIPTION

The alternator pulley receives motion by drive shaft pulley by means of transmission belt. Tension adjuster
is mounted on the rear part of the alternator itself.
This adjuster is sealed, therefore maintenance is not possible.

6.4.2 OPERATION

The electrical operation of group alternator-rectifier-tension adjuster is the following. By rotating the alternator
pulley, an alternate tension is produced in the stator windings due to rotor remaining magnetism.
Diodes in rectifier bridge transform stator alternate tension into direct tension between terminal (B+)
connected with the batteries and ground.
Alternator rotation speed increases and electrical current is supplied for battery charge and user feeding.
A part of the generated output is sent to inductor winding and controlled by the tension adjuster to allow
alternator output feeding in the different charge conditions.

6.4.3 FEATURES

Output 24V 50A

Rotation clockwise

F7006
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ES8-6-5

ELECTRIC COMPONENTS EX135W

6.4.4 MAINTENANCE PRECAUTIONS

Follow the indications herebelow to avoid diode or transistor damage:

• Do not disconnect batteries with the engine running. This would cause a sudden tension change in alternator
charge system, producing serious damage.
• Do not disconnect any electrical wire before the engine stops and before all switches are in OFF position.
• Do not short-circuit by connecting electrical wires to wrong terminals. Always identify the correct terminal
before the connection. A short-circuit or a wrong connection generating a reverse polarity causes serious
damages.
• Do not search for tension by means of sparkle contacts.

6.4.5 PROTECTION FUSE

The electrical system includes a fuse Link 80A for alternator protection, mounted on the alternator itself.
60406991
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ES8-6-6

ELECTRIC COMPONENTS EX135W

6.5 STARTER

6.5.1 DESCRIPTION

The starter essentially includes:

• an electromagnetic switch for pinion connection on crown teeth and electrical contacts closing;
• a real electrical motor including fixed windings (inductors) and mobile windings on rotor (induced);
• a return device for pinion connection.

6.5.2 ELECTRICAL FEATURES

Voltage 24 V

Rotation clockwise

Control electromagnetic

Power 4 kW

6.5.3 PROTECTION FUSE

The electrical system includes a fuse Link 40A for start-up spool protection.

60406991
21599

F7005
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ES8-7-1

CONTROL LINES EX135W

7 CONTROL LINE AND WIRING HARNESSES

7.1 PILOT LEVER CONTROL

7.1.1 TB/EX POSITIONER CONTROL LINE

PARTS INVOLVED:

Solenoid valve B3 - B4
Switch SW1
Lamp L16
Fuses 33 - 25 - 28 - 37
R.h. pilot lever
Pressure switch P6
Relay R16
SMC control unit
Controller Box
60406991
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ES8-7-2

CONTROL LINES EX135W

7.1.2 GRASS-CUTTER CONTROL LINE (OPTIONAL)

PARTS INVOLVED:

Solenoid valve A4 - A5 - A6
Fuses 9 - 32
R.H. pilot lever
Relay R27 - R15 - R14
Switch SW6 - SW9

60406991
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ES8-7-3

CONTROL LINES EX135W

7.1.3 HYDRAULIC HAMMER CONTROL LINE

PARTS INVOLVED:

Solenoid valve A5
Fuses 9
R.h. pilot lever
Relay R27
Switch SW6

F7423
60406991
21599
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ES8-7-4

CONTROL LINES EX135W

7.1.4 CONTROL LINE FOR CLAMSHELL BUCKET SWING

PARTS INVOLVED:

Fuse 9
R.H. pilot lever
Relay R22 - R23
Solenoid valve C1 - C2

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 21599 60406991

7.1.5 CRUSHER CONTROL LINE (OPTIONAL)

PARTS INVOLVED:

Fuse 33 - 25 - 28 - 37
Controller Box
Switch SW1
R.h. pilot lever
Relay R16 - R14 - R15
Solenoid valve B3 - B4 - A4
Pressure switch P6
Control unit SMC
Bulb L16

R.H. PILOT LEVER

CONTROL LINES EX135W
ES8-7-5
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7.1.6 L.H. STABILIZER CONTROL LINE

PARTS INVOLVED:

Fuse 31 - 32
L.h. pilot lever
Relay R9 - R18 - R13 - R14 - R15
Solenoid valve B1 - B2 - A4

SWITCH PANEL

L.H.
PILOT LEVER
CONTROL LINES EX135W
ES8-7-6

21599 60406991
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 21599 60406991

7.1.7 R.H. STABILIZER CONTROL LINE

PARTS INVOLVED:

Fuse 31 - 32
Relay R9 - R18 - R13 - R14 - R15
L.h. pilot lever
Solenoid valve B1 - B2 - A3

SWITCH PANEL
CONTROL LINES EX135W

L.H.
PILOT LEVER
ES8-7-7
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ES8-7-8

CONTROL LINES EX135W

7.1.8 HORN LINE

PARTS INVOLVED:

Fuse 15
Relay R15
L.h. pilot lever
Horn
Horn switch SW.2

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 21599 60406991

7.1.9 BLADE CONTROL LINE

PARTS INVOLVED:

Fuse 31 - 32
L.h. pilot lever
Relay R9 - R18 - R13 - R14 - R15
Solenoid valve B1 - B2 - A3

SWITCH PANEL
CONTROL LINES EX135W

L.H.
PILOT LEVER
ES8-7-9
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ES8-7-10
CONTROL LINES EX135W

7.2 SWITCH PANEL CONTROL

7.2.1 SLOW TRAVEL CONTROL LINE (Tortoise)

PARTS INVOLVED:

Solenoid valve A3
Two-speed switch
Fuse 32 - 31
Pressure switch P3
Relay R9 - R18 - R13
APC 50

SWITCH PANEL

KICK DOWN PRESSURE SWITCH OPERATION

Travel Kick down Gear downshift Gear upshift
pedal pressure switch 2nd → 1nd 1nd → 2nd
Forw. pressed W/power contr.

Gear control lever

on aut.transm.
to ab. 1/2 press. < 20 bar 20 revs 520 revs
stroke contact open

Forw. pressed W/power contr.

to end-of- press. < 20 bar 220 revs 550 revs
stroke contact open

F8771gb

L.h. Note: The operation signal of kick down pressure switch is

pilot valve sent to gearbox control unit (APC50) only when the hare
control is selected

60406991
21599
Kick down pressure switch
- Contact normally open
- Setting 20 bar
- Tolerance + 1 bar
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ES8-7-11
CONTROL LINES EX135W

7.2.2 FAST TRAVEL CONTROL LINE (Hare)

PARTS INVOLVED:

Solenoid valve A3
Two-speed switch
Fuse 32 - 31
Pressure switch P3
Relays R9 - R18 - R13
APC 50

SWITCH PANEL

KICK DOWN PRESSURE SWITCH OPERATION

Travel Kick down Gear downshift Gear upshift
pedal pressure switch 2nd → 1nd 1nd → 2nd

Gear control lever

Forw. pressed W/power contr.

on aut.transm.
to ab. 1/2 press. < 20 bar 20 revs 520 revs
stroke contact open

Forw. pressed W/power contr.

to end-of- press. < 20 bar 220 revs 550 revs
stroke contact open

F8771gb

Note: The operation signal of kick down pressure switch is sent

to gearbox control unit (APC50) only when the hare control is
L.h. selected
pilot valve
60406991
21599

Kick down pressure switch

- Contact normally open
- Setting 20 bar
- Tolerance + 1 bar
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ES8-7-12

CONTROL LINES EX135W

7.3 BRAKE PEDAL CONTROL

7.3.1 BRAKE SIGNAL CONTROL LINE (Stop lights)

PARTS INVOLVED:

Solenoid valve D1
Fuse 28 - 26
Pressure switch P2
Relay R4
Switch SW1

60406991
21599
F11158
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ES8-7-13

CONTROL LINES EX135W

7.3.2 WORK BRAKE CONTROL LINE

PARTS INVOLVED:

Solenoid valve D1
Fuse 28 - 26
Pressure switch P2
Relay R4
Switch SW1
60406991
19400

F11156
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ES8-7-14

CONTROL LINES EX135W

7.3.3 AXLE LOCK CONTROL LINE (Disengaged)

PARTS INVOLVED:

Solenoid valve A2
Fuse 28
Switch SW1

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ES8-7-15

CONTROL LINES EX135W

7.3.4 PARKING BRAKE CONTROL LINE FROM FRAME EX135W 77WM0072 (MONOBOOM VERSION)
EX135WT 77WT0078 (TRIPLE ARTICULATION VERSION)

PARTS INVOLVED:

Solenoid valve A0 - A4
Fuse 28 - 31
Pressure switch P7
Relay R5 - R28
Switch SW1
Lamp L2
APC 50
60406991
21599

A0 SOLENOID VALVE
NORMALLY CLOSED
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ES8-7-16

CONTROL LINES EX135W

7.3.4 TRAVEL BRAKING CONTROL LINE

PARTS INVOLVED:

Solenoid valve C2
Fuse 33 - 25 - 35 - 31
Relay R10
Lamp L14 - L15
Controller Box
Pressure switch P4 - P5

GEAR SELECTION
CONTROL

60406991
21599
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ES8-7-17

CONTROL LINES EX135W

7.3.5 CONTROL LINE FOR BRAKE SYSTEM FAILURE

PARTS INVOLVED:

Fuse 28
Lamp L7
Pressure switch P1
Buzzer
60406991
19400

F11157
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ES8-7-18

CONTROL LINES EX135W

7.3.6 BRAKE SYSTEM PRESSURE INDICATOR LINE

PARTS INVOLVED:

Fuse 2 - 3 - 28
SMC control unit
EC angle sensor
Pressure sensor
Buzzer
P/M indicator

60406991
21599

PRESSURE SENSOR
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ES8-7-19

CONTROL LINES EX135W

7.4 STEERING COLUMN CONTROLS

7.4.1 ROTATING BEACON CIRCUIT LINE

PARTS INVOLVED:

Fuse 28
Lamp L13
Switch SW4
Relay R8
Rotating beacon
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ES8-7-20

CONTROL LINES EX135W

7.4.2 CONTROL LINE FOR EQUIPMENT PILOTING DISCONNECTION

PARTS INVOLVED:

Fuse 28
Lamp L12
Relay R11 - R5
Solenoid valve A1
Switch SW5

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ES8-7-21

CONTROL LINES EX135W

7.4.3 TIPPING CIRCUIT LINE (Optional)

PARTS INVOLVED:

Fuse 9
Lamp L10
Switch SW7
Buzzer
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ES8-7-22

CONTROL LINES EX135W

7.4.4 START-UP CIRCUIT LINE

PARTS INVOLVED:

Fuse 17 - 15 - 16 - 18 - 1 - 3 - 4
Relay R2 - R17
Diodes D1 - D2 - D4 - D5 - D6
Timer IVECO

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CONTROL LINES EX135W

7.4.5 TRAVEL CONTROL LINE (Start-up key in OFF position)

PARTS INVOLVED:

Fuses 32 - 33 - 25 - 31 - 35 - 36
Relay R9 - R5 - R18 - R13 - R10 - R16 SWITCH PANEL
Controller Box
APC 50
Lamp L14 - L15 - L16
Switch SW1
Solenoid valve A3 - B3 -
B4 - C2 - A - B - C
Pressure switches P3 - P4 - P5 GEAR SELECTION CONTROL

L.H. PILOT
LEVER

HOURMETER

R.H. PILOT
LEVER
60406991
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CONTROL LINES EX135W-EX165W

7.4.6 WINDSHIELD WIPER CIRCUIT LINE

PARTS INVOLVED:

Fuse 1 - 6 - 12
Windshield wiper relay box
Monitor
Windshield washer electr. pump
Windshield wiper

60406991
19400
F11159
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ES8-7-25

CONTROL LINES EX135W

7.4.7 CONTROL CIRCUIT LINE FOR TEMPERATURE AND PRESSURE LEVELS

PARTS INVOLVED:

Fuse 1 - 6
Monitor
Air filter clogging sensor
Engine high water temperature sensor
Hydraulic oil level sensor
Engine water level sensor
Engine oil level sensor
Engine oil low pressure sensor
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CONTROL LINES EX135W

ELECTRICAL SYSTEM DESCRIPTION

1. Batteries 40. High engine coolant temperature sensor

2. Battery isolator relay 41. Hydraulic oil level sensor
3. Stater motor 42. Engine coolant level sensor
4. Starter relay 43. Engine oil level sensor
5. Fuse 4 (BOX B) 40 A 44. Fuel level sensor
6. Key-start switch 45. Engine coolant temperature sender
7. Diode 1 46. Low engine oil pressure sensor
8. Diode 6 47. Relay R13
9. Diode 2 48. Relay R14
10. Electrical stop 49. Relay R15
11. Horn button 50. Relay R22
12. Horn relay R7 51. Diagnostic tool connection (Dr. EX)
13. Windscreen washer electrical pump relay 52. Engine speed hand control
14. Horn 53. (SMC) main controller unit
15. Fuse 1 (BOX A) 40 Amp 54. E button (Economy mode)
16. EC motor 55. Relay R23
17. Left-hand control lever 56. Engine speed control unit
18. Alternator relay R1 57. Anti-load dump relay R3
19. Right-hand control lever 58. Safety relay R2
20. Windscreen wiper 59. Relay R27
21. Windscreen washer electrical pump 60. Electrical fuel lift pump
22. Cab light 61. Engine speed control unit panel light
23. Fuse box 62. Optional equipment connector
24. Relay R21 (opt) 63. Engine speed pedal enabling connector
25. Radio 64. Air conditioner pressure switch
26. Cigar lighter 65. Hour-counter
27. Windshield wiper control unit 66. Engine coolant temperature gauge
28. Boom light (opt) 67. Fuel level gauge
29. Boom light 68. Instrument panel lighting
30. Blade relay R18 69. Engine oil level warning light
31. Boom light relay R6 70. Engine coolant level warning light
32. Alternator 71. Hydraulic oil level warning light
33. Diode 6 72. Battery charge malfunction warning light
34. Fuse 3 (BOX B) 80 A 73. Low engine oil pressure warning light
35. Electrical fan and control 74. High engine coolant temperature warning light
36. Engine stop coil relay R17 75. Buzzer
37. Diode 5 76. Blade solenoid valve
38. Gear control lever 77. Air filter restriction warning light
39. Air filter restriction sensor
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CONTROL LINES EX135W

78. Low fuel level warning light 118. Relay R28

79. Windscreen wiper safety switch 119. Synchro-start relay
80. Angle (EC) sensor 120. Relay R11
81. Auto/idle engaged light (led) 121. Diode 4
82. E mode engaged light (led) 122. Relay R20
83. Stabilizer solenoid valve 123. Heated filter warning light (opt)
84. Programming switch connector 124. Relay R19
85. Level check button (CHECK) 125. Fuse 2 (BOX A) 40A
86. Buzzer stop button 126. Relay R8
87. Windscreen washer control button 127. TBG horn (opt)
88. Windscreen wiper control button 128. Relay R24
89. Work lights control button 129. TBG pressure switch (opt)
90. Blade/stabilizer solenoid valve 130. Cab lights (opt)
91. Blade/stabilizer solenoid valve 131. Relay R26
92. Solenoid valve for left bucket swing 132. Engine stop solenoid timer
93. Solenoid valve for right bucket swing 133. Relay R25
94. Hammer solenoid valve 134. Relay R4
95. Grass-cutter solenoid valve 135. Steering column
96. Crusher solenoid valve + TB 136. High pressure brake pressure switch
97. Crusher solenoid valve + TB 137. Stop lights brake pressure switch
98. Controller box 138. Work brake solenoid valve
99. Air conditioner control panel (opt) 139. Front lights
100. Air conditioning system (opt) 140. Front direction indicators
101. Auto/idle control button 141. Rear lights
102. Gear governor APC50 142. Number plate light
103. Relay R10 143. Loud-speakers
104. Solenoid valve C2 144. Aerial
105. Brale solenoid valve 145. Direction indicator
106. First and second speed solenoid valve 146. Emergency light switch
107. Clutch disconnection solenoid valve 147. Light switch
108. Travel speed sensor 148. Brake mode switch
109. Synchronization pressure gauge 149. Complete control module
110. Kick-down pressure switch 150. Travel speed selector
111. Unused warning light 151. Automatic windscreen wiper connector
112. Pressure switch 152. Connector (normally open) (opt)
60406991

113. Relay R9 153. Rotating beacon

114. Air conditioning compressor engage control 154. Travel pedal control check solenoid valve
21599

(opt) 155. Equipment control check solenoid valve

115. Relay R5 156. Axle lock solenoid valve
116. Relay R16 157. Pressure switch for solenoid operation A0
117. Accumulator charge sensor 158. Grass-cutter swiwtch (opt)
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CONTROL LINES EX135W

NOTES:

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ES8-7-30

CONTROL LINES EX135W

LOWER FRAME ELECTRIC CABLE
60406991
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F9256
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ES8-7-31

CONTROL LINES EX135W

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ES8-7-31
ES8-7-32

CONTROL LINES EX135W

RELAY ELECTRIC CABLE
60406991
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F9258
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ES8-7-33

CONTROL LINES EX135W

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INDEX EX135W - 9 - 1

SECTION 9 TROUBLESHOOTING

CONTENTS

Group 1 - INTRODUCTION ......................................................................................... TS9-1-1

1.1 General information

Group 2 - HYDRAULIC SYSTEM TROUBLESHOOTING.............................................. TS9-2-2

2.1 Generalities
2.2 Front attachment
2.3 Swing
2.4 Travel
2.5 Brake system
2.6 Steering system
2.7 Drive axles
2.8 Transmission

Group 3 - ELECTRICAL SYSTEM TROUBLESHOOTING ............................................ TS9-3-1

3.1 Electrical system components

3.2 Relays and fuses
3.3 Checks on electrical components
3.4 Pilot electronical circuit checks
3.5 Brake system electrical circuit checks
3.6 Travel control electrical circuits checks
3.7 Stabilizers control electrical circuits checks
3.8 Blade control electrical circuit checks
3.9 Positioning control electrical circuit checks
60406991

3.10 Hammer control electrical circuit checks

3.11 Axle lock electrical circuit checks
21599

3.12 Monitor failed to operate with start-up key in "on" position

3.13 Throttle control electrical circuit checks
3.14 Diesel engine failed to start
3.15 Transmission control electronic unit (APC 50) checks
3.16 Test harnesses kit 75301702
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TS9-1-1

INTRODUCTION EX135W

1. INTRODUCTION

1.1 GENERAL INFORMATION

These six basic steps are essential for efficient

troubleshooting:

1. Study the system.

2. Ask the operator.
3. Inspect the machine.
4. Operate the machine yourself.
5. Perform troubleshooting.
6. Trace possible causes.

1.1.1 STUDY THE SYSTEM

Study the machine’s technical manuals. Know the

system and how it works, and what the construction,
functions and specifications of the system components
are.

1.1.2 ASK THE OPERATOR

Before inspecting, get the full story of malfunctions from

your star witness-the operator.

(a) How is the machine being used? (Find out if the

machine is being operated correctly).

(b) When was the trouble noticed, and what types of

work the machine doing at that time?

(c) What are the details of the trouble? Is the trouble

getting worse, or did it appear suddenly for the first
time?

(d) Did the machine have any other troubles previously?

If so, which parts were repaired before?

1.1.3 INSPECT THE MACHINE

Before starting the troubleshooting procedure, check

the machine’s daily maintenance points, as shown in
the operator’s manual.
60406991

Also, check the electrical system, including the batteries,

as troubles, in the electrical system such as low battery
21599

voltage, loose connections and blown fuses will result in

malfunction of the controllers, causing total operational
failure of the machine.
Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
inspection.
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TS9-1-2

INTRODUCTION EX135W

1.1.4 OPERATE THE MACHINE YOURSELF

Try to identify the trouble by operating the machine

yourself.
If the trouble cannot be confirmed, stop the engine and
obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the wire
harnesses.

1.1.5 PERFORM TROUBLESHOOTING

CAUTION: Never attempt to disconnect harnesses

or hydraulic lines while the engine is running. The
machine may malfunction or pressurized oil may spout,
possibly resulting in personal injury. Be sure to stop the
engine before disconnecting harnesses or hydraulic
lines.

With the information obtained from the above operations

of point (1) to (4), and with the help of following
diagnosing diagrams, perform the check and
measurements in order to identify the causes of the
malfunction.

1.1.6 TRACE POSSIBLE CAUSES

Before reaching a conclusion, check the most likely

causes again. Try to identify the actual cause of the
trouble.

Based on your conclusion, make a plan for appropriate

repairs to avoid consequent malfunctions.
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TS9-2-1

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

• For the hydraulic system general diagram, refer to the diagram attached at the end of section 7.

• For the electrical system general diagram, refer to the diagram attached at the end of section 8.
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TS9-2-2

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2. HYDRAULIC SYSTEM TROUBLESHOOTING

2.1 GENERALITIES
2.1.1 NO ACTUATORS MOVE WHEN CONTROL LEVERS ARE OPERATED
No

Confirm that pilot

shut-off lever of arm
rest is in the work
condition and micro
No
switch on armrest Check fuse 28.
is effective.
No

Verify the A1 Replace fuse.

solenoid valve on
Yes utility solenoid
valves assembly is
excited.

Yes

No
No actuators mo- Does engine sound
ve when control change when
No Check for air being
levers éare control lever is
sucked at main
operated. operated?
pump suction port.
3*
Yes Is hydraulic oil level
low?

Yes

Check for
Yes effectiveness of
control valve
spools?
Check if pilot
pressure setting is
No normally?
1* Check if pilot pump
60406991

is functioning
No normal.
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TS9-2-3

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Unlock pilot shut-

off lever on armrest
to the work
condition.
Check for efficiency
Yes of electrical line. No Replace solenoid
Yes Check the solenoid valve A1 and/or
valve A1. electrical line.
Check for R11 relay No
Replace R11 relay.
efficiency.
Yes
Check for effi-
Replace
ciency of neutral-
izer button. neutralizer button.

2*
No Check the priority Yes
Confirm the pilot Go to 1*.
valve.
system pressure
at port P on utility Clean or replace
solenoid valves No the priority valve.
assembly. Clean or replace
Yes solenoid valve A1.

No Repair or replace
Check for main main pump.
No
pump suction
strainer clogging.
Clean suction
Yes strainer.

Repair main pump

Yes suction port.

Check for hydraulic Add hydraulic oil/

oil leakages. repair leakages.

Yes
Go to 2*.

Clean control val-

No No ve spools.
Replace pilot filter.
Yes Check for pilot filter Yes Replace brake
Check brake valve.
clogging. valve.
60406991

Yes Clean suction

Check for pilot strainer.
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pump suction filter

clogging. Check
No steering pump Check pump
pressure. driving spline and
coupling. Replace
No pilot/brake and
steering pump.
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TS9-2-4

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.1.2 ACTUATOR DOES NOT STOP WHEN THE PILOT VALVE LEVER IS RETURNED TO NEUTRAL

Yes Replace or repair

pilot valve.
Check if, with pilot
Actuator moves shut-off lever on the
when the pilot armrest in the Replace solenoid
valve is returned to locked position valve A1 on utility
neutral. (safety), actuator Yes solenoid valves
stop to move. Check leakage with assembly.
solenoid valve A1,
on utility solenoid
No valves assembly,
excited. Actuator is
No
internally leaking.

Control valve spool

is abnormal. Repair
or replace control
valve.

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TS9-2-5

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

1.3 OIL TEMPERATURE IS ABNORMALLY HIGH

Yes Provide correct

operating
Check if pilot shut instructions.
off lever on armrest
is in work
condition. Chek full-flow filter Yes Replace hydraulic
for presence of components as
No metal chips, etc. necessary.

No
Yes Clean oil cooler or
Is oil cooler or net net.
in front of oil cooler Is an object
clogged? blocking the oil Yes Remove blocking
No cooler or engine object.
compartment?

No
Yes
Adjust fan belt.

Is fan belt slip- Is hot air circulating

ping? in opposite direc-
tion because, for Yes
Replace.
example, of broken
No partition surround-
ing oil cooler?
No

Disassemble and
Yes Replace bypass
relief valve.
check oil cooler
bypass relief to see
if it is damaged or Is return line clog- Yes Disassemble and
for drop in setting ged? check.
No
pressure.
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TS9-2-6

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.2 FRONT ATTACHMENT

2.2.1 SOME OF THE CYLINDERS DO NOT MOVE WHEN PILOT CONTROL VALVE IS OPERATED

Yes Replace the

Check if main
pressure is cylinder.
Yes supplied to the
cylinder.
(Pressure gauge Replace control
on cylinder supply). No valve spool.

Check if the
Is pilot pressure
Yes solenoid valve A1
supplied to control
of utility solenoid
valve spool pilot Yes
valves assembly is
chamber?
actuated.

Check if pilot
pressure setting is
No normally.

Does
non-functioning Check priority valve
No
cylinder hold in for correct
neutral position? operation.

Yes Repair or replace

cylinder.

Is overload relief
No valve normal?
Replace over load
No relief valve.
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TS9-2-7

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Yes Repair or replace

the pilot control
Check pilot valve.
Yes pressure to the port
P of pilot control
valve. Check the deriver
No block for free flow.

Replace solenoid
valve A1 or repair
No electrical system.

Yes Clean or replace

hydraulic pilot filter.

Check pilot pres-

Yes
sure to port P on
brake pedal.

Replace brake
No valve.
Replace priority
No valve.
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TS9-2-8

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.2.2 FRONT ATTACHMENT MOVEMENTS ARE SLOW

No

Yes Is engine fast idle

rpm normal?

Yes

Check if operation
mode control is
normal.

No
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TS9-2-9

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Check engine fuel Check engine

filter and air filter. speed.

Yes Carry out the main

Check the ∆p pump flow test.
No between port M and
LS signal of main
pump should 21 Set the ∆p values
bar. on main pump.
Is hydraulic pilot No
pressure lower
than normal?
Repair or replace
pilot relief valve on Check the priority
Yes utility solenoid No valve.
valves assembly.

Check the
Yes compensator related
to the actuator on
control valve, clean
Check the input
or replace.
pilot pressure of the
control spool
related to the slow
actuator on the
control valve.
Check the pilot line.
No
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TS9-2-10

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.2.3 NO DIGGING POWER

Yes Is hydraulic oil level

low?

Yes Does pump make

abnormal noises?

No

Do all actuators fail

to provide digging
power?

Replace overload
Does only one relief valve with one
actuator fail to from a functioning
No provide digging actuator.
power? Does problem
disappear?
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TS9-2-11

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Yes
Add hydraulic oil.

Yes
Repair suction line.

Is there looseness
No in suction line?
Pump is abnormal
or suction strainer
No is clogged.

Check correct set

adjustment of the
No Load Sensing
valve (280 bar) and
main over pressure
Is main pump pres-
valve.
sure normal?

Check the main

Yes pump flow.

Yes Replace overload

relief valve.

Yes Check spool of

control valve for
cleanliness.
Is the pilot pressure
input on the spool
No of control valve
normal?

Check the pilot line.

No
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TS9-2-12

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.2.4 ACTUATOR DROPS NOTICEABLY WHEN THE PILOT CONTROL VALVE IS PLACED IN NEUTRAL

Pilot valve output

Yes pressure is
improperly adjusted.
Repair or replace.

Does phenomenon
change when
Yes Replace overload
engine is stopped?
relief valve.
Replace tempo-rarily
for test purpose only,
the overload relief
valve with one from a
No functioning
Yes Repair or replace
actuator.Does
problem disappear? control valve.
Is control valve
spool damage, e.g.
No broken spring or
loose bolt? Repair or replace
No cylinder.

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TS9-2-13

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.2.5 ACTUATOR DROPS BRIEFLY WHEN STARTING OPERATION

In slight operation,
attempt to lift the
front falling in the Malfunction in control
direction of gravity. valve.
(This is easily Repair or replace.
checked when
engine is stopped).
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TS9-2-14

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.3 SWING

2.3.1 SWING IS NOT SMOOTH

The output pilot

Yes pressure from pilot
control valve is not
delivered linearly.
Is phenomenon
Yes reversed when right
and left pilot hoses
are interchanged?

No

Yes Swing is rough in

one direction only.

Yes Is swing motor

drain amount
normal?

Is swing parking
brake release
No pressure normal?

Is only swing
function rough? No

Check secondary
60406991

No (also blade and/or stabilizer) pump.

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TS9-2-15

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Replace the throttle

No valve one way ø 0.8
mm on control
Check operation of valve left body.
Yes the throttle valve
one way ø
0.8 mm on control
valve left body.
Check the control
Yes valve spool.

Check or replace
the pilot control
No valve.

Check the control

valve spool.

Yes Check setting of

the swing over
pressure valve.

Check swing mo-

No tor.
Check operation of
Yes throttle valve - one
way on swing
Check pilot
motor.
pressure on pilot
circuit downstream
shuttle valve on
swing motor.
Check shuttle valve
No operation.
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TS9-2-16

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.3.2 NO SWING MOTION

Is pilot pressure
Yes delivered to swing
overpressure val-
ve inlet?

Is pressure at left
Yes pilot control valve
ports 1 and 3
normal?

No

Yes Are all functions

other than swinging
normal?

Only swing function

and blade
stabilizer do not
move?
Confirm that pilot
shut-off lever on
armrest should in
work position and No
that swing lock
lever is released.
No function work.
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No
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TS9-2-17

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Yes Swing device is

abnormal.
Check oil level.
Yes Is swing motor
drain overflowed
When the swing is normal in amount?
actuated, is the Repair or replace
No pressure delivered swing motor.
to the swing No
parking brake
Does machine not release normal?
Yes swing even though Check pilot circuit.
No
swing motor is
rotating?
Check swing
device (connection
Yes between pinion and
gear).

Yes Control valve spool

sticking.
Repair or replace.
Is swing motor
drain amount
No normal?
Repair or replace
No swing motor.

Repair or replace
left pilot control
valve.

Check secondary
pump operation.

Go to paragraph
60406991

1.1.1
21599

Move the pilot

shut-off lever to
work position.
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TS9-2-18

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.3.3 SLOW/WEAK SWINGING POWER

Yes

Both swing
acceleration and
left swing brake are
Yes
incorrect, or both
left swing
acceleration and
right brake are
Swing acceleration incorrect. Acceleration force
is slow. is not available but
No braking force is
normal.

No swing power in
one direction.

No
Uphill swing on a
slope cannot be
done.
All functions other
than swing and blade
and/or stabilizer
No movement are
normal.

Is pilot pressure
Yes setting normal?

Swing power is If all other func-

decreased when tions are normal,
arm is moved dur- control valve may Check control
ing combined be abnormal. valve.
swing/excavation Check control
operation. valve.
60406991
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If all other func-

Swing is slow dur- tions are normal,
Check control
ing combined there may be ab- Measure line sup-
valve and swing
swing and boom normal pressure ply pressure.
motor.
lift operation. loss in swing cir-
cuit.
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TS9-2-19

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Yes Check swing over Adjust or replace

pressure valve swing over pres-
Does phenomenon sure valves.
setting.
reverse when the
supply hoses to
swing motor are
interchanged?
Replace swing
No motor.

No Repair or replace
control valve.
Is phenomenon
reverse when right
and left pilot hoses Yes Repair or replace
are interchanged control valve.
Check if the
on swing motor?
operation of the pilot
Yes control valve is
normal? Repair or replace
No pilot control valve.

Check secondary
pump.

No Check pilot circuit

and pilot control
valve.

Yes Does swing motor

Yes
Is the pressure
delivered to port
of swing parking
Yes brake shuttle val-ve
normal?
Repair or replace
drive pressure is
Is the pressure swing motor.
normal?
delivered to port
swing parking bra-
ke release valve
while swing lever Repair or replace
operated? shuttle valve and/
No or throttle valve.

Check pilot circuit.

No
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TS9-2-20

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.4 TRAVEL

2.4.1 DOES NOT TRAVEL (Other functions normal)

Test conditions:
- transmission speed gear selection in 1st or 2nd speed;
- speed selector in reduced or normal speed;
- parking brake switch disengaged;
- pedal pilot control valve pressed.

Pressing the pedal

control valve for
forward travel and for
reverse travel , check
pilot pressure to the
Yes
ports T1 and T2 on
Control Valve that
should be
proportional to the
Check pilot circuit
pedal stroke (70 bar).
and the solenoid
valve A0 position
and selection
solenoid valves B3
position that
should be in way
to allow free flow
Check power sup-
of pilot line. ply wiring harness
to the selection so-
lenoid valves B3.
Check correct op-
No eration of selection
solenoid valves B3
on pilot pressure
line of pedal control
valve.
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TS9-2-21

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Check transmission
Yes and control clutch
efficiency.

Yes Check efficiency of

travel motor.
Check the supply
pressure to the
Yes travel motor ports Check travel mo-
tor and reduction
A and B and the
No gear assembly.
actuation of travel
relief valve.
Check Control
Valve for travel
No control spool
correct operation.

Check hydraulic
pilot circuit.
No Check pedal pilot
control valve.
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TS9-2-22

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.4.2 REDUCED TRAVEL POWER (Other functions normal)

Ensure that the conditions of the machine and electrical controls are checked prior to initiate other
troubleshooting operations. Check operation of parking brake, solenoid valve A0, travel pressure switches,
solenoid valve A3 and solenoid valve C.

The travel overpressure valves work both at

350 bar Parking brake or
service brake
sticking.

Interchange Yes Faulty overpres-

temporarily for test sure valve
purpose only, the adjustment.
Yes Only one is 350 bar overpressure valve
(A → B).
Then try again. Are
condition changed?
No

Is the travel over

pressure adjustment
normal? Both travel overpressure valves work less than
350 bar
- Normal pressure:
350 bar.
- Travel pedal
completely
actuated.
- Gear speed
selector on 1st or
2nd speed. Set overpressure
- Normal speed valve on travel
(rabbit). No motor.
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TS9-2-23

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Yes Check the rotary

joint for internal
leakages.
Check output
pressure on line A
or B of control valve
if the over pressure
valves do not work.
Is the output
pressure normal?

Check travel
No control valve spool.

Check travel motor

speed.

No

Check or replace
travel motor.
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TS9-2-24

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.4.3 MACHINE MOVING ALSO WITHOUT ACTUATING THE TRAVEL PEDAL

If the travel pedal is not actuated, under normal operating conditions, the oil pilot pressure against the "travel
control" spools of the control valve is about zero; consequently there is no travel.

Yes Faulty control

valve.
Is the pilot pressure
on travel spools of
control valve
normal?
Is the pilot pressure
about zero with no
actuation of travel
pedal? Faulty travel pedal
No pilot control valve.

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TS9-2-25

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.5 BRAKE SYSTEM

2.5.1 BRAKE SERVICE FAULTY

Reduce pressure acting on ad-

Wrong pressure
Strong braking. juster located under pedal, meas-
setting. uring pressure with a gauge.

Increase pressure acting on

adjuster located under pedal,
Wrong pressure
Poor braking. measuring pressure with a gauge;
setting.
TAKE CARE not to exceed
pressures set for brakes.

Insufficient feeding
Delayed braking
and discharge
and braking High viscosity of the brake oil.
speed of the
release.
brakes.

Minimum pressure
Fluctuating of the accumulators Check correct setting of
braking pressure. is lower than max. accumulators pressure.
brakes pressure.

Check nitrogen pressure of

accumulators, after discharging
Accumulators with oil from them, using the
nitrogen precharge appropriate instrument than
low or too high. recharge. It is possible to measure
the pressure of the nitrogen
Continuous reading the pressure of the last
recharge of portion of oil being discharged.
accumulators.
60406991

Leakage on feeding
Remove leakage.
accumulators Lines.
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TS9-2-26

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Check the sliding of all parts, in

detail of the charging accumulator
input valve.

A foreign body
prevents the sliding
The accumulators Check hydraulic connections for
of accumulator
do not charge. leakages.
charging valve in
the brake pedal.

Check, following overhaul of

accumulator charge valve, the
correct position of stop ring of
plunger located in front of feeding
connection.

Check the brake valve for free

Drain of brake drain. Disconnect hose N
valve not free. connection to hydraulic oil tank to
check free flow.

Brake stay on.

Check that setting of pedal stop
allows a small play between
linkage and actuating pistons.
Pedal does not
return.

Eliminate possible clogging inside

the chamber under the pedal.

The indicator on Check adjustment pressure

the steering Check pressure switch, located on charge valve,
column does not setting. the pressure setting should ensure
give any signal. 3 or 4 brakings from indicator
coming ON.

Sudden changes of
Shocks felt on Check free flow to the hydraulic oil
pressure on
pedal. tank.
discharge.
60406991

Incorrect adjustment Inspect the disc thickness and if

Insufficient braking. or brake discs worn the discs are usable readjust
out. brakes.
21599

Loss of hydraulic Check and repair any leaks in

brake fluid. outside circuit or on cylinders.
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TS9-2-27

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Soft brake pedal. Air in brake circuit. Bleed brake circuit.

Too small of a Readjust the brake.

brake discs gap.

Carry out brake

Oil leaks from
Oil overheating pedal adjustment
brake pedal
with consequence or replace the
assembly when not
of vaporisation. brake pedal
actuated.
assembly.

Damage on supply
or drain circuit Replace pipes.
pipes (Restrictions
or bendings).

2.5.2 WORK BRAKE FAULTY

Work brake Check electrical

Work brake does solenoid valve on operation of work No Replace the
not operate. brake pedal brake solenoid valve solenoid valve.
assembly faulty. D1, located on brake
pedal assembly,
when the switch on
dashboard is pushed.

Yes
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Check brake valve

Replace the brake
pressure in work
valve assembly.
mode.
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TS9-2-28

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.5.3 PARKING BRAKE FAULTY

Disconnect the parking

brake solenoid valve (A)
located on
Transmission control
assembly.
Check the electrical
power supply circuit to Disconnect parking
the solenoid valve: brake hose (SAHR) Check parking
a)Parking brake from the rear axle. brake (SAHR)
The parking brake Connect a pressure
Yes
disengaged: adjustment on rear
does not operate gauge and connect axle.(refer to
in spite of the - Solenoid valve
actuated. again the hose. Sect.5).
parking brake Check the pressure
button is actuated, - Hydraulic connection
between
Yes conditions:
or does not a) Parking brake
disengaged in Transmission control
assembly and rear engaged:
spite of the parking Check hydraulic
axle open. - Pilot pressure not
brake button is pilot pressure on
b)Parking brake available.
released in rest port (2),and free No
engaged: b) Parking brake
position. No flow from drain
- Solenoid valve not disengaged:
output (O) and drain
actuated. - Pilot pressure
line to hydraulic
- Hydraulic connection available.
tank.
between
Transmission control Yes
assembly and rear
axle close.
Repair or replace
the transmission
control assembly.

2 A O
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Transmission control assembly

F4072
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TS9-2-29

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Check pilot
Check operation of Yes pressure input at Yes Replace brake
priority valve. port P on brake valve assembly.
valve assembly.
No
No

Check pilot filter

and pilot/brake
Repair or replace
gear pump.
the priority valve.

Transmission control
assembly
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F7716
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TS9-2-30

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.6 STEERING SYSTEM

2.6.1 STEERING WHEEL HEAVY

Yes Is steering cylinder

working normally?

Are front tyres

inflated to correct
working pressure?

No

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HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Pressure setting of
Yes valve defective.
Replace steering
valve.
Yes Is steering pump
pressure normal?

Pump defective.
No Replace pump.

Faulty steering
No cylinder.

Correct inflating
pressure of tyres
(refer to Operation
and Maintenance
Manual).
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TS9-2-32

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.7 DRIVE AXLES

2.7.1 NOISE

Noise during coast

Wheel bearings Replace faulty
and under power
damaged. items.
is the same.

Low lubricating oil Refill oil to proper

level. level.

Inspect through
rear cover. Replace
Ring and pinion
and adjust pinion
worn.
and ring (see Sect.
Noise under power 5).
greater than during
coast.

Worn ring and Replace faulty

pinion bearings. items (see Sect. 5).

Worn planetary Replace faulty

gears or bearings. items (see Sect. 5).

Inspect ring, pinion

and pinion bearings.
Loose pinion nut. If undamaged,
retighten nut as
described in Sect.
Noise during 5.
coast greater than
under power.

Only one bearing Replace faulty

damaged. items.
60406991
21599

Worn spider and/or Replace faulty

Noise during turn.
side gear. items.
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TS9-2-33

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Inspect and replace

Worn or damaged
cardanshaft. transmission
cardanshaft.

Inspect for wheel

and wheel stud
damage. Replace
Loose wheel(s). if needed and re-
tight the lug nuts to
the foreseen tight-
ening torque.

A noise (Stick slip)

Ball joint at steering Inspect and replace
when going from
knuckle damaged. damaged items.
forward to reverse.

Inspect through
Spider pins loose
in differential car- rear cover. Replace
rier. the damaged
items.

Differential side
Replaced
gear washers
damaged items.
worn.
60406991
21599
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TS9-2-34

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2 . 7 . 2 AXLE RELEASE FAILED

When the A2 front axle locking control solenoid valve and located on utility solenoid valves assembly is not
energised , the front axle is in lock condition.
Axle locking operates when the work brake , parking brake , axle locking . are actuated.
With work brake or parking brake switch actuated, the axle locking is operated.

No
Check fuse 28. Replace fuse.

Is output pressure
Yes at port A2 of utility
Yes
solenoid valves
Is input pressure at assembly normal?
Yes port P of utility
solenoid valves
assembly normal?

Check pilot line.

The work brake, No
parking brake and
axle locking switch
is normal.

Axle locking switch

actuated. The
indicator is turned
on. No
The axle lock
operates (solenoid
valve A2 (EV13) de-
energised) also
actuating the work
brake or parking
brake button.
To check electrically
the switches and
indicators on central
dashboard. Make
reference to
electrical system
troubleshooting.
60406991
21599
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TS9-2-35

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

Yes Replace the

axle locking
Is input pressure assembly.
Yes at port P of axle
locking assembly
normal?
Check line
leakage and
No rotary joint.
If the electrical
control signal
correctly comes
to the elec-trical
connector A2
(see electrical
No system
troubleshooting),
replace the
solenoid valve
A2 .

Buttons or wiring
harnesses faulty..

3 1
3 5
6 2

F11160
60406991

4
4
1 - Utility solenoid valves assembly
19400

2 - From pilot/brake gear pump

3 - Rotary joint
4 - Axle locking assembly
5 - Solenoid valve A2 (EV13)
6 - Tank
7 - Pressure reducing valve
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TS9-2-36

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.8 TRANSMISSION

2.8.1 CONTROL SHIFTING CYLINDER HYDRAULIC CHECK

Connect a pressure
gauge (A) on input oil
supply line to the
shifting cylinder (B)
with hydraulic pilot
pressure already
checked and first Check the operation
speed gear engaged. No of solenoid valves
On pressure gauge control transmission
should be read about assembly.
35/40 bar.
With second speed
gear engaged should
be read 0 bar.

Yes

Hydraulic pressure
input to control
shifting cylinder is
normal.

60406991
21599
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TS9-2-37

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

HYDRAULIC TRANSMISSION CIRCUIT

7
6
11 10
2 12

12 1
C

3 3
13 B 9 8

18 5 2
4 0
17
1
14 A B C
B

F 4
15
16
P
D

1 2

F7138

1 - Hydraulic oil tank 10 - Hydraulic travel motor

2 - Pilot/brake gear pump 11 - Transmission and rear axle assembly
3 - Pilot filter 12 - Cylinder clutch control
4 - Brake valve assembly 13 - Clutch
5 - Priority valve 14 - Shifting cylinder
6 - To the utility solenoid valves assembly 15 - Speed gear engaged switch
60406991

7 - Rotary joint 16 - Speed sensor

8 - Transmission accumulator 17 - To the parking brake (negative)
9 - Solenoid valves control transmission 18 - Clutches
21599
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TS9-2-38

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

2.8.2 HYDRAULIC CONTROL CLUTCH TEST

Connect a pressure
gauge (A) on
control clutch line
(C) with hydraulic
pilot pressure
already checked,
Check the operation
perform a speed
No of solenoid valves
shifting 1st ⇒ 2nd
control transmission
and 2nd ⇒ 1st.
assembly.
On pressure gauge
should be read a
peak of pressure of
about 35/40 bar in
relation with the
speed shifting.

Yes

Hydraulic pressure
input to control
clutch cylinder is
normal.

C
60406991

A
21599
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TS9-2-39

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

P
1st speed 2nd speed 1st speed

~ 35/40 bar

Pressure on shift-
ing cylinder control
0 t line

~ 35/40 bar

Pressure on clutch
0 control line
t

Typical diagram of hydraulic operation of transmission

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TS9-2-40

HYDRAULIC SYSTEM TROUBLESHOOTING EX135W

NOTES:

60406991
21599
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TS9-3-1

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3. ELECTRICAL SYSTEM TROUBLESHOOTING

3.1 ELECTRICAL SYSTEM COMPONENTS

3.1.1 CONTROL UNITS

1 - SMC control unit

2 - Fuses
3 - Controller
4 - Windshield wiper control unit
5 - Transmission control electronic
unit (APC50)
6 - Relay box
7 - Diodes

5
4

1
2 3
2

F7139

6
7
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TS9-3-2

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.1.2 ELECTRICAL COMPONENTS IN THE CAB

4 8

10 3

F7140
7

9
60406991
21599

1 Radio - 2 Antenna - 3 Loudspeakers - 4 Windshield washer tank with electrical motor pump - 5 Windshield wiper
motor - 6 Cigarette lighter - 7 SMC control unit - 8 Ceiling light - 9 Supplementary 12 Volt power socket - 10 Electric
fan.
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TS9-3-3

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

14
7
12
1

13
10

2
3
4

9
5

11
F7021
60406991
21599

1 Control buttons in left pilot valve - 2 Control buttons on right pilot valve - 3 Control module - 4 Switch and indicator
panel 1 - 5 Key starter switch - 6 Switch and indicator panel 2 - 7 Central dashboard - 8 Windshield wiper control
lever - 9 Transmission control lever - 10 Lights and horn control lever - 11 APC50 control unit - 12 Horn switch -
13 Axle lock brake switch - 14 Emergency lights switch.
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TS9-3-4

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.1.3 ELECTRICAL COMPONENTS ON THE FRAME

2
1

E
C

3
F7307
60406991
21599

1 Throttle control - 2 Fuel level sensor - 3 Hydraulic oil level sensor.

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TS9-3-5

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

Detail A

F11161
1 Pressure switch, brakes system insufficient pressure signal P6 (90 bar) - 2 Pressure switch, stop lights P2 (5 bar)
- 3 Work brake solenoid valve D1.

Detail B 1
3
2

1 - Pressure switch (Kick down) (P3)

2 - Pressure switch (Reverse travel) (P4)
3 - Pressure switch (Forward travel) (P5)
4 - Brake pressure trasducer (PT)

F7308

Detail C

1
1
60406991
19400

1 - Batteries
2 - Switch, batteries cut-off.
F7309
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TS9-3-6

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

Detail D

F7313

1 Utility solenoid valves assembly.

Detail E

1 4
3 6

2 5
60406991
21599

F4077

1 Left hand pilot control selector solenoid valve - 2 Solenoid valve B1 - 3 Solenoid valve B2 - 4 Position solenoid
valve - 5 Solenoid valve B3 - 6 Solenoid valve B4.
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TS9-3-7

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.1.4 ELECTRICAL COMPONENTS ON THE ENGINE

3
1

6
7

4
5

2
9

10

F7717
60406991
21599

1 Coolant level sensor - 2 Coolant temperature sensor (S1) - 3 Thermistor, max. coolant temperature - 4 Engine oil
pressure switch - 5 Engine oil level sensor (L3) - 6 Stop electric motor - 7 Injecton pump - 8 Alternator - 9 Starter
motor - 10 Air filter clogging sensor (S3).
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TS9-3-8

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.1.5 ELECTRICAL COMPONENTS ON THE UNDERCARRIAGE

4
5

3
1

2
F7718
60406991
21599

1 Speed sensor (cardan) - 2 Speed gear engaged switch (synchroniser switch) - 3 Transmission control unit - 4
Braking control solenoid valve - 5 Rotary joint.
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TS9-3-9

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.1.6 ROAD LIGHTS AND WORKS LIGHTS

Note: For electrical diagrams and reference lines see section 8.

12

7
6
5
1
3
2
4 2
1
7
6

8
10

9
11

F7321

1 Front turning light - 2 Front light - 3 Side light bulb - 4 Low beam/high beam bulb - 5 Front direction light bulb -
6 Side light - 7 Side light bulb - 8 Rear reflector - 9 Rear light - 10 Rear direction light bulb - 11 Stop/tail light - 12
Work light.
60406991
21599
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TS9-3-10

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.2 RELAYS AND FUSES

3.2.1 RELAYS

RY1 Alternator relay

RY2 Safety relay
RY3 Anti Load Dump relay
RY4 Working brake relay
RY5 Parking brake relay
RY6 Lights-boom relay
RY7 Horn relay
RY8 Rotating beacon relay
RY9 Safe start-up relay
RY10 Gear light relay
RY11 Pilot control relay
RY12 OPT relay
RY13 Switch A relay
RY14 Switch B relay
RY15 Switch C relay
RY16 Auto Idle relay
RY17 Engine stop relay
RY18 Blade shift
RY19 R.h. direction indicator relay
RY20 L.h. direction indicator relay
RY21 Cab lights R.h. relay (OPT)
RY22 Switch F relay
RY23 Switch E relay
RY24 Upper beams relay
RY25 Lower beams relay
RY26 Parking lights relay
RY27 Switch K relay
RY28 Parking brake relay

RY1 RY8 RY15 RY22

RY2 RY9 RY16 RY23 A B C D

RY3 RY10 RY17 RY24
60406991

RY4 RY11 RY18 RY25

RY5 RY12 RY19 RY26

21599

RY6 RY13 RY20 RY27

RY7 RY14 RY21

A B C D RY28

F7312
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TS9-3-11

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.2.2 FUSES
Fuse Rating
PROTECTED CIRCUIT
No. (AMP)
FUSES IN THE BOX

1 Function memory 5
2 Engine control 10
3 Step-by-step motor 10
4 Power supply 5
5 Pump control solenoid 5
6 Switch panel 5
7 OPT
8 OPT
9 Bucket rot. & overturn sensor 5
10 Cab lights (opt) 10
11 Upper lights (opt) 20
12 Wind screen wiper 10
13 Heater 20 20 19 18 17 16 15 14 13 12 11

14 OPT
15 Horn 5 10 9 8 7 6 5 4 3 2 1
16 Radio 5
17 Cigarette-lighter 10
18 Ceiling light 5
19 Air conditioner (opt) 10 40 39 38 37 36 35 34 33 32 31
20 OPT
21 R.H. parking light 5
30 29 28 27 26 25 24 23 22 21
22 L.H. parking light + ceiling light 5
F5666
23 Traffic beams 10
Upper beams
24 10
(not used for homologation)
25 Case (1) 20
26 Stop lights 5
27 OPT
28 Steering column panel 5
60406991

29 Boom lights 5
30 Rotating beacon 5
19400

31 Gearbox card 10
32 L.H. knob 10
33 Case (2) 5
34 Socket 10
F5684gb
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TS9-3-12

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

Fuse Rating
PROTECTED CIRCUIT
No. (AMP)
FUSE 3 FUSE 1
FUSES IN THE BOX

35 Solenoid C2 5

36 Emergency lights 10

37 Positioner valve 5

38 Heated sat (opt) 10

39 OPT

40 OPT FUSE 4 FUSE 2

F5667
CENTRAL UNIT FUSES
FUSE

Main power supply with key 40

1
BOX A
FUSE
2

Heated fuel filters 40

FUSE

Engine start-up line

80
3
BOX B

protection
FUSE
4

Engine shut-down protection 40

F11639gb

60406991
19400
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TS9-3-13

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.3 CHECKS ON ELECTRICAL COMPONENTS

3.3.1 SOLENOID VALVE CHECKS

The efficiency check of the solenoid valves essentially consists of performing the checks of the relevant
system that they control.
Table 1 shows the solenoid valves list, the name, the function and the hydraulic and electrical reference
designation and the troubleshooting paragraph to which need to refer for carrying out the efficiency check of
the single solenoid valves.

TABLE 1

Location Name Function

Utility solenoid valves assembly

Solenoid valve A0 Parking brake and travel exclusion

Solenoid valve A1 Pilot system exclusion

Solenoid valve A2 Axle locking

Solenoid valve A3 Travel speed changing and blade/stabiliser

control selector valve

Solenoid valve A4 Left and right side stabiliser selector valve

Solenoid valve A5 Hammer control or grass-cutter

Solenoid valve A6 Grass-cutter control

Selector solenoid

Solenoid valve B1 Left hand pilot control selector valve - Blade - Stabilizers
Solenoid valve B2 Left hand pilot control selector valve - Blade - Stabilizers
valves

Solenoid valve B3 Positioner selector

Solenoid valve B4 Positioner selector

pedal control solenoid
Transmission

Solenoid valve "A" Parking brake

valves

Solenoid valve "B" Speed gear shifting

Solenoid valve "C" Clutch control

assembly
Brake

Solenoid valve D1 Work brake

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TS9-3-14

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.3.2 PRESSURE SWITCHES CHECKS

The efficiency check of the single pressure switch is quoted in the check of the relevant system that is included.
Table 2 shows the pressure switches list, the function, the electrical reference designation and the
troubleshooting paragraph to which need to refer for carrying out the efficiency check of the single pressure
switch.

TABLE 2

Name Function

Pressure switch (P6) Pilot valve

Pressure switch (P4) Travel (reverse)

Pressure switch (P5) Travel (forward)

Pressure switch (P1) Brake failure

Pressure switch (P2) Stop light

Pressure switch (P3) Kick down

Pressure switch (P7) Parking brake

60406991
21599
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TS9-3-15

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.3.3 RELAY CHECKS

The efficiency check of the single relay essentially consists of performing the checks of the relevant system
on which they are installed.
Table 3 shows the relays list installed on the switching control unit, their function, the electrical reference
designation and the troubleshooting paragraph to which need to refer for carrying out the efficiency check of
the single relays.

TABLE 3

RY1 Alternator relay

RY2 Safety relay
RY3 Anti Load Dump relay
RY4 Working brake relay
RY5 Parking brake relay
RY6 Lights-boom relay
RY7 Horn relay
RY8 Rotating beacon relay
RY9 Safe start-up relay
RY10 Gear light relay
RY11 Pilot control relay
RY12 OPT relay
RY13 Switch A relay
RY14 Switch B relay
RY15 Switch C relay
RY16 Auto Idle relay
RY17 Engine stop relay
RY18 Blade shift
RY19 R.h. direction indicator relay
RY20 L.h. direction indicator relay
RY21 Cab lights R.h. relay (OPT)
RY22 Switch F relay
RY23 Switch E relay
RY24 Upper beams relay
RY25 Lower beams relay
RY26 Parking lights relay
RY27 Switch K relay
RY28 Parking brake relay
60406991
21599
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TS9-3-16

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.4 PILOT ELECTRONICAL CIRCUIT CHECKS

3.4.1 WITH PILOT SYSTEM EXCLUSION SWITCH NOT ACTUATED AND SEAT L.H. ARM REST
LOWERED, THE PILOT CIRCUIT DOES NOT OPERATE.
(Solenoid valve A1check)

Test condition:
- Hydraulic circuit checked
- Arm rest lowered in work position
- Pilot system button not actuated
- Parking brake released

Check if voltage is
Check operation of Check no voltage Check operation
Yes 24 V on connector Yes Yes
is on relay R11, of relay R5.
fuse 28. column F terminal
terminals 85 and
5.
86.
No No
No Check feeding
operation and
connections on
Check circuit. solenoid valve A1
Replace the fuse. Check operation located on service
of switch SW5. solenoid valve
group.
Replace solenoid
valve.

Yes
Check if voltage is
24V on relay R11
in 87A.
Yes Check switch
No located under
armrest.

No

Replace relay Replace switch.

R11.

Pilot control
solenoid valves
assembly A1
60406991
21599

F7402
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TS9-3-17

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

SOLENOID VALVE A1 CONTROL CIRCUIT

690

663

261
658

Control
panel
664

F8951
60406991
21599
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TS9-3-18

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.5 BRAKE SYSTEM ELECTRICAL CIRCUIT CHECKS

3.5.1 STOP LIGHTS DO NOT OPERATE

Test condition:
- Bulbs lights checked
- Brake pedal pressed

Check switch
SW1.

No

Press brake pedal

and check if
Check if voltage is voltage is + 24V Check if there is no Check if voltage is
Check operation of Yes + 24 V between Yes Yes voltage between Yes 24 V on relay R4,
between pin 708
fuse 26. pin 707 and nega- and negative. terminals 85 and terminal 87A.
tive. 86 of relay R4.
No Yes No
No
No
Replace relay R4.
Check circuit. Replace pressure
Replace fuse. Check wiring har- switch.
ness. Check for line and
rear light
operation.

P2
60406991
19400

Stop lights pressure switch (P2)

- Normally open contacts
Setting = 5 ±0.5 bar
F11162
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TS9-3-19

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

+24 VOLT
26

Stop light pressure switch

P2

707 708

675

R4

709
E-3

G-4 685
Steering column
D-1

710
28

LH stop L10 21W L5 21W RH stop

light light
+24 VOLT
60406991
21599

F7320
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TS9-3-20

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.5.2 BRAKE FAILURE INDICATOR MALFUNCTION

Test condition:
- Accumulators discharged
- thermal engine running

Check for wiring

Yes Check if voltage is Yes Check if voltage is Yes
Check operation harness opera-
24 V between 711 24 V between 681
of fuse 28. tion. Replace buz-
and negative. and negative. zer.
No No
No

Check the circuit.

Replace the fuse. Check wiring har- Replace pressure
ness. gauge P1.

Brake failure pressure switch (P1)

- Normally closed contacts
Setting = 90 ± 5 bar

1 2

P1
F11163
60406991

OFF
15 20
10 25 P
19400

5 Km/h 30

Brake failure
indicator (L2)
F7406
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TS9-3-21

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

+24 VOLT
28

Brake failure pressure switch

P1
711

681

Steering
D-6

column

L2
60406991

F7376
21599
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TS9-3-22

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3 5 . 3 WORK BRAKE MALFUNCTION

Test condition:
- switch in working brake position
- brake accumulator discharged

Check if voltage is Check if voltage is Check if voltage is

Yes Yes 24V on solenoid
Check operation 24V on 690 of 24V on 675 and
Yes valve D1 connector.
of fuse 28. brake switch. ground.

No No
No
No Yes

Check for wiring Replace switch Check and/or

Check the circuit.
harness opera- SW1. replace solenoid
Replace the fuse. tion. valve.

Check for wiring

harness opera-
tion.

1 2

OFF
15 20
10 25 P
P

5 Km/h 30

0
60406991

Work brake
indicator (L3)
19400

F7406

Work brake solenoid

valve D1

F11164
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TS9-3-23

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

+24 VOLT
28

675

677

R4

685 710

690 E-3

SW1
677

W P
D1
T A/L

L3 G-4
60406991

D1
F7377
21599
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TS9-3-24

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.5.4 THE MACHINE IS ALWAYS BRAKED

Test condition:
- Thermal engine running

Check if voltage
No is 24V on 764 Check if voltage
Check wiring har- Yes
and ground on Check opera- Yes is 24V on 690
ness. Check if voltage
terminal 30 of tion of fuses 28 and ground on
relay R28. and 31. Yes is 24V between
switch SW1.
wire 678 and
Yes No ground.
No Yes
Check if voltage Check if voltage Check for wiring
Check and/or Yes is 24V on sole- Check if voltage No
is 24V on termi- harness operation.
replace A0. noid valve A0 Yes nal 87 relay R28, Yes is 24V on relay Replace switches.
connection. wire 674. R28 and termi- Check the circuit.
nals 86 and 85
Yes Replace the
No on 698 and 729.
fuse.
Check if voltage
No is 24V on termi-
Replace relay No Check wiring har- No
Check wiring har- Replace R28. box. ness. nal 86 of relay
ness. R5 wire 673.
Check the opera-
tion of pressure Yes
switch P7 and
wiring harness.

No
Replace pres-
sure switch.
Check if voltage
Check if voltage Yes is 24V on wire
Check if voltage Yes is 24V on con- 730 of terminal
is 24V on pin 4 nector 16 of 87 relay R5.
Check if voltage
Check wiring wire (744) of APC50 on wire
No is 24V on sole- Yes APC50, with 730. No
harness and rota- noid valve A4
ting joint. connector. parking brake
No
released.
Yes
No
Check and/or
Replace wiring Replace relay
replace.
harness. R5.

Replace APC50.

4 3 A
1

60406991
21599
F4073

1 - Transmission control assembly

3 - Parking brake solenoid valve
4 - Port marked with parking brake feeding 4
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ES8-7-25

CONTROL LINES EX135W

7.4.7 CONTROL CIRCUIT LINE FOR TEMPERATURE AND PRESSURE LEVELS

PARTS INVOLVED:

Fuse 1 - 6
Monitor
Air filter clogging sensor
Engine high water temperature sensor
Hydraulic oil level sensor
Engine water level sensor
Engine oil level sensor
Engine oil low pressure sensor
60406991
21599
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TS9-3-26

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.6 TRAVEL CONTROL ELECTRICAL CIRCUITS CHECKS

3.6.1 THE NORMAL/REDUCED SPEED (HARE/TORTOISE) SELECTION DOES NOT OCCUR

Solenoid valve A3 check

Check if voltage is
24 V on terminal 86
Check operation of of relay R9 wire Yes
Yes Set switch in
fuses 31 and 32. 740. position .
Check there is no
No
No supply on terminal
Check wiring har- 86 and 85 of relay
ness. R9 and terminal
87A cable 734 is
Check the circuit. No negative.
Replace the fuse. Replace relay.
Yes

Check wiring har-

ness.

No

Replace solenoid
valve.
Check if terminal 30
Yes No of relay R18 cable
Check wiring har-
ness. 734 is negative.

Check if voltage is Yes

24V on solenoid
valve A3 con-
nector on cable
791.

Yes Check wiring and No

relay R18. Check if terminal 85
of relay R13 cable
Check if voltage is 780 is negative.
24V on terminal Yes
87 of relay R13
cable 791.
No

Replace relay
R13.
Utility solenoid valves assembly

60406991
21599
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TS9-3-27

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

REDUCED/NORMAL SPEED SELECTION CIRCUIT

770 736
740 733

778

42 734

778
783 / 787

770

780

791
781

F9023
60406991
21599

Notes:
Relay R9: - excited with normal speed button (HARE)
actuated.

- not excited with reduced speed button

(TORTOISE) actuated.
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TS9-3-28

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.6.2 WITH THE FORWARD CONTROL PEDAL PRESSED AT STROKE END, THE SIGNAL FROM KICK
DOWN PRESSURE SWITCH IS NOT SENT TO THE APC50 CONTROL UNIT
Kick down pressure switch circuit check

Check conditions:
- Kick down pressure switch hydraulically checked: contacts in closed position with pressure higher than 20
bar on travel pilot control line.
- Pilot/brake hydraulic circuit checked.
- Normal speed control button (rabbit) actuated and selector gear speed in automatic position (make
reference also to the transmission control unit input signals checking.

Check switch in
. Check if
voltage is 24 V on
Check operation of terminals 86 and
Yes Yes Check for a nega-
85 of wire 740
fuse 31. tive on terminal 1
and 42 of relay No Check wire conti-
of kick-down pres-
No R9. nuity.
sure switch.
No
Yes
Check the circuit.
Replace the fuse. Check switch
and and rela-
tive wiring.
Check for a nega-
tive signal on
termi-nal 17 of
APC50 wire 743
with engine runn-
ing and travel
pedal to the end-
Check wiring bet- No of-stroke.
Replace pressure Yes ween kickdown
switch. pressure switch
and APC50 con-
trol unit.

KICK DOWN PRESSURE SWITCH OPERATION

Travel pilot Kick down Speed gear down- Speed gear up-
control valve pressure switch shift 2nd ⇒ 1st shift 1st ⇒ 2nd

with pilot
Speed gear selection

Forward pressed pressure lower

lever to automatic

to lower than 1/2 than 20 bar: 20 rpm 520 rpm

stroke
60406991

contacts open

with pilot
21599

Forward pressed pressure higher 220 rpm 550 rpm

to stroke-end than 20 bar:
Kick down pressure switch contacts closed
- Normally Open contacts
- Setting: 20 bar Note: The kick down pressure switch actuating signal is sent to the
- Tolerance + 1 bar Transmission control unit (APC50) only when normal speed
(Hare) is selected.
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TS9-3-29

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

740

42
736 735
741

742

744
743
745
746 671
684

757
758

F9024
60406991
21599

Notes:
Relay R9: - excited with normal speed button (HARE)
actuated.

- not excited with reduced speed button

(TORTOISE) actuated.
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TS9-3-30

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.6.3 BRAKING EFFECT NOT AVAILABLE DURING FORWARD TRAVEL WITH 2ND GEAR ENGAGED AND
HARE POSITION
Solenoid valve C2 travel motor braking

Check conditions:
- Transmission in manual position.

Check if contact is Check if voltage is

Check operation
Yes open in pressure Yes 24 V on terminal1
of fuses 33 and
switch P5. wire 765 of Con-
25.
troller Box, with
No travel pedal press-
No ed forward and
Replace fuse. that voltage is 0 V
Replace pressure after 5 seconds
switches. travel pedal has
been released.

No

Replace Controller
Box.

2
60406991
21599

1 - Rotary joint
2 - Solenoid valve C2 braking control
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TS9-3-31

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

639 706

737

755

765

763
60406991

F9025
21599
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TS9-3-32

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.7 STABILIZERS CONTROL ELECTRICAL CIRCUITS CHECKS

3.7.1 R.H. SIDE STABILIZERS DO NOT OPERATE

Solenoid valves A4 and B1 - B2 check

Check if voltage is
24 V on terminal
86 of wires 774 Check if voltage is
Check operation of and 776 relay R15 24 V between Check if voltage is
Yes and terminal 30 Yes Yes 24 V between ter-
fuses 32. terminals 86 and
wires 772 and 85 with button C minal 87 and
774. pressed. ground.
No
No Yes No
No
Replace relay
R15.
Check wiring.
Replace button on
pilot lever. Check if voltage is
24 V between
wires 793 and 930
with button C
pressed.

Check the circuit. Yes

Replace the fuse.
Check and/or re-
place solenoid.

Check if voltage is Check if voltage is

24 V between ter- Check if voltage is
24 V on terminal
minals 86 and 85 Yes 24 V between ter-
86 of wires 776 Yes
with button C minal 87 and
and 777, relay
pressed. ground.
R14 and terminal
B1 B2
30 wires 771 and
772. Yes Yes No

No Replace button on Replace relay

pilot lever. R14.

Check wiring.
P2 P1

Check if voltage is
C
T 24 V on wires 792
and 922 with
F7389 button C pressed.
L.H. pilot control selector
solenoid valve Yes
60406991

Check and/or re-

Utility solenoid valves place solenoid.
assembly A4
21599

F7392
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TS9-3-33

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

STABILIZERS CONTROL CIRCUIT DIAGRAM

24 VOLT
32
776
774

772
774

777
776

771

772
R15 R14
794

783

D3

D3

781

782
922
792

923
793

6 785
790 930
1
789

L.H. PILOT
60406991

CONTROL
21599

B1 B2
A4

F7382
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TS9-3-34

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.7.2 L.H. SIDE STABILIZERS DO NOT OPERATE

Solenoid valves B1 and B2 check

Check if voltage is
24 V on terminal
86 wires 776 and
777 relay R14 and Check if voltage is Check if voltage is
Check operation of
Yes terminal 30 wires Yes 24 V between Yes 24 V between
fuse 32. terminals 86 and
771 and 772. terminal 87 and
85 with button B ground.
No No pressed.
Yes No
No
Check wiring. Replace relay
Check the circuit. Replace button on R14.
Replace the fuse. pilot lever.

Check if voltage is
24 V between
wires 792 and 922
with button B
pressed.

Yes

Check and/or re-

place solenoid.

B1 B2

P2 P1

T
60406991

F7389

L.H. pilot control

selector solenoid valve
21599

F7391
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TS9-3-35

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

STABILIZERS CONTROL CIRCUIT DIAGRAM

24 VOLT
32
776
774

772
774

777
776

771

772
R15 R14
794

783

D3

D3

781

782
792

922

923

6 785
790
1
789
60406991

L.H. PILOT
CONTROL
21599

B1 B2

F9026
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TS9-3-36

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.8 BLADE CONTROL ELECTRICAL CIRCUIT CHECKS

3.8.1 BLADE DOES NOT OPERATE

Solenoid valves A3, B1-B2 check

Check if voltage is
24 V on terminal
86 wires 776 and Check if voltage is
774 relay R14 and Check if voltage is
Check operation of 24 V between
Yes terminal 30 wires Yes Yes 24 V between
fuse 32. terminals 86 and
771 and 772. terminal 87 and
85 with button A
No ground.
pressed.
No
No Yes No

Replace relay
R14.
Check wiring.

Replace button on
pilot lever. Check if voltage is
24 V between
wires 792 and 922
with button A
pressed.

Check the circuit. Yes

Replace the fuse. Check and/or re-
place solenoid.

Check if voltage is Check if voltage is

24 V on terminal 24 V between Check if voltage is
86 wires 778 and terminals 86 and 24 V between
Yes Yes
777 relay R13 and 85 with button A terminal 87 and
terminal 30 wires pressed. ground.
B1 B2
770 and 771.
No Yes No
No
Replace button on Replace relay
pilot lever. R13.

Check wiring.
P2 P1

T Check if voltage is
24 V between
F7389 wires 791 and 929
L.H. pilot control with button A
pressed.
A
selector solenoid valve
Yes
60406991

Utility solenoid
valves assembly A3 Check and/or re-
21599

place solenoid.

F7393
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TS9-3-37

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

BLADE CONTROL CIRCUIT DIAGRAM

778

R18
24 VOLT

779
783
787
32

778
777
770

771
R13
777
776

771
772

780
791
R14
783

D3

D3
D3
791

781
929

782
922

923

6
792

790 785

789 1

L.H. PILOT
CONTROL
A3
60406991

B1 B2
21599

F7383
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TS9-3-38

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.9 POSITIONING CONTROL ELECTRICAL CIRCUIT CHECKS

3.9.1 POSITIONING CONTROL DOES NOT OPERATE

Check if voltage Check for nega-

is 24 V with ne- tive on terminal
Check opera-
Yes gative on termi- Yes of Controller
tion of fuses 25
nals 8 and 5 of Box wire 636 by
and 37. No Check and/or
Controller Box pressing button
No wire 639 e 706. D of left pilot replace button.
lever.
Check the circuit.
Replace the No Yes
fuse.
Check wiring.
From terminal 2
of Controller Replace
No
Box,voltageshould Controller Box.
be 24 V with
button pressed.

Yes

No Check if voltage
Check wiring.
is 24 V on sole-
noid valves B3
and B4 connec-
tors, wires 637
Check and/or Yes and 920; 820
replace sole- and 921.
noids B3 and
B4.

B3 B4

D
60406991

P2 P1
21599

F7394

F7395
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TS9-3-39

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

POSITIONING CONTROL CIRCUIT DIAGRAM

639

706

635

629
643

636

637
920
820
921 F9027
60406991
21599
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TS9-3-40

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.10 HAMMER CONTROL ELECTRICAL CIRCUIT CHECKS

3.10.1 HAMMER CONTROL DOES NOT OPERATE

Solenoid valve A5 check

Check if voltage
is 24 V with ne-
Check operation gative on termi-
Yes No
of fuse 9. nals 86 and 30 Check wiring.
No of relay R27
wires 630 and
647.

Check the circuit. Yes

Replace the
fuse.

Check if voltage
is 24 V between
terminals 85 Check wiring
and 86 wires No and button K of
630 and 649 by pilot lever.
Check wiring
pressing button
and switch SW6
K located on left
operation.
hand pilot lever.
No
Yes
Check if voltage
is 24 V on sole-
noid valve A5 Yes
connector, wires Check if voltage
652 and 924. is 24 V on Replace relay
switch SW6 No
R27 and check
Yes wire 650 with wiring.
button K press-
ed.
Check and/or
replace sole-
noid A5.

Utility
solenoid
valves A5
K assembly
(front side)

K
60406991
21599

F7396 F7397
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TS9-3-41

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

HAMMER CONTROL CIRCUIT DIAGRAM

24 VOLT
9

630
648

648
647

R27

R.H. PILOT
CONTROL VALVE
650

K
649

SW6

A6
652
924
60406991
21599

A5

F7385
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TS9-3-42

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3 . 1 1 AXLE LOCK ELECTRICAL CIRCUIT CHECKS

3.11.1 WITH AXLE LOCK SWITCH ACTUATED, THE AXLE UNLOCK DOES NOT OPERATE

Check if voltage is Check if voltage is

24 V between ne- 24 V on connector
Check operation of gative wire and E1 negative wire
Yes 690 on connector Yes 686 with switch No Check and/or
fuse 28.
D1 of switch SW1. SW1 in OFF posi- replace SW1.
No tion.
No Yes
Check the circuit.
Replace the fuse. Check wiring.

Check if voltage is
Yes 24 V on connector
Check and/or re-
of solenoid valve
place solenoid A2.
A2 wires 686 and
931.
No

Check wiring.

Utility solenoid
valves assembly A2
60406991
21599

F7398
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TS9-3-43

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

AXLE LOCK CIRCUIT DIAGRAM

24 VOLT
28
690

W P
D1
AXLE LOCK COMMUTATOR SW1

T A/L

E1
686
931
60406991
21599

F7386
A2
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TS9-3-44

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.12 MONITOR FAILED TO OPERATE WITH START-UP KEY IN "ON" POSITION

Test condition:
- Disconnect connection on windshield wiper monitor.

Check on monitor Check on monitor

Check operation Yes Yes if voltage is 24 V Yes Replace and/or
of fuses 1 and 6. if voltage is 24 V
between wire 9- in C1, C2 and check monitor.
No 11-20 on "Wiper C12.
Box".
No
No

Replace fuses.

Check wire bet-

Check if voltage is
No ween "Wiper Box"
Check wire. 24 V on pin 10 of
and monitor.
"Wiper Box".

Yes

Replace and/or
check "Wiper Box".

60406991
21599
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TS9-3-45

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.13 THROTTLE CONTROL ELECTRICAL CIRCUIT CHECKS

3.13.1 FAILURE OF EC MOTOR SENSOR

No Faulty SMC main

Check for control unit.
interruptions or
short-circuits
Yes between terminal
no. D15 della con-
nessione del SMC
ed il terminale n. 2
Disconnect EC del sensore EC. Wiring failure
sensor between SMC and
Yes EC sensor.
connector.
Yes Check if voltage
between
terminals no. 1
Disconnect EC
and no. 3 of Wiring broke
sensor con-
wiring No
nector. between SMC
connection is 5±
Check if resistance Check if voltage and EC sensor
0,5 V.
between termi- between terminals terminal no. 3.
nals no. 1 and no. • Key switch: ON no. 1 of wiring
3 of EC sensor No connection and
connector is 1,7 ± machine frame is
0,4 KΩ. 5±0,5 V. Wiring broke bet-ween
SMC and EC sensor
Connect test wiring Yes terminal no. 1.
with the two EC • Key switch: ON
s e n s o r • 5±0,5 V for voltage
connectors. change reference
Turn engine speed values.
control and check
if voltage varies
as prescribed.
EC sensor faulty.
No
• After replacement see
TS9-3-47

• Unless stated otherwise, set the switches as follows:

Engine Button E Working Auto-idle Button E

control mode button
speed selector
Turned to General Engine control
OFF OFF
max. posit. mode speed

• For measurements use Dr. EX.

• Sensor operation range.

60406991

F7399
21599

Item Control required/Button operation

Engine control speed Min. speed 0.3 - 1.0 V

Max. speed 4.0 - 4.7 V
EC sensor Engine speed control at min. position 2.5 ± 0.05 V
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TS9-3-46

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.13.2 EC MOTOR FAILURE

24 25 Item Control required/Button operation

about 3 ÷ 6V about 3 ÷ 6V
12 26
Engine speed control Minimum speed position 0.3 -1.0 V
39 65 72
Step motor
machine wire
connection + S - Maximum speed position 4.0 - 4.7 V

Step Motor angle EC sensor Speed control turned to minimum 2.5 ± 0.05 V
wire connection

2.5 ± 0.05V
Check lines
823, 822 and
682 and opera-
tion of brake oil
pressure sen-
sor.
Check linkage
No Yes from Step Motor
With wire dis- to injection pump.
Carry out pro- connected
Check Led gram procedu- from Step Mo-
blinking on
Yes re. tor voltage is
about 24V. Disconnect
SMC control 1. Turn start-
Check voltage Yes connection to
unit. up key to Connect SMC Check line and
No on Step Motor SMC control unit Check connec-
OFF posi- control unit and relative con-
Yes connection (3 and check: Yes check feeding Yes Yes tion voltage in Yes
tion and wait nection between Failure in SMC
÷ 6V of the two -perfect insula- engine speed
for at least on (+) D1, D2 SMC control unit control unit.
Check the two tion of Step Mo- control and SMC.
Check 10 seconds. circuits with A13 and B7. and engine speed
circuits of Step tor control wi-
operation of 2. Set Learn- connection control. No
Motor with about res; No
fuses 2, 3, 4, 5 ing switch in engaged).
No 5,7 Ohm (wire - angle sensor No
located in fuse ON position disconnected (see page TA9-
box. (up). from the system). 3-45. Check the con-
3. Turn start-
up key to cerned line. Reset line and/or
No relative connec- Reset the line
ON position.
tion or engine where the failure
4. Wait for at
Replace fuses. speed control. has been found.
least 10 se-
conds.
5. Set Learn-
ing switch in

60406991
OFF
position
(central).

21599
6. Turn start-
up key to
OFF posi-
Check Step Motor
tion.
and replace if
No necessary.
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TS9-3-47

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.13.3 ENGINE SPEED ADJUSTMENT AND ENGINE PROGRAMMATION

When the following repairs or operations are

performed, or when engine speed is out of the
recommended range, adjust speed and program
the engine.

• When engine, engine control cable or Ec motor

are removed.
• When the main control unit (SMC) is replaced.

Engine speed adjustment:

1. Turn engine speed control knob to the minimum

position (Voltage of EC angle sensor is 2.5 V).
2. Turn start-up key to START and start the
engine. (Note: Turn air conditioner switch to Fixing
OFF). bolt
3. Untighten control lever fixing bolt to EC motor
Control lever
output shaft.
4. While checking the real engine speed with Dr.
EX or a tachometer, adjust control lever to
obtain the prescribed engine min. speed. For
adjustment values refer to Performance Test
section.
5. Tighten the bolt to secure the control lever to
EC motor output shaft.

Tightening torque: 13 Nm (1.3 Kgm)

NOTE: Make sure EC motor output shaft is not

covered with oil or grease.

6. Program the engine

Rear
Engine programmation: object holder case

1. Turn start-up key to OFF position and wait for

at least 10 seconds. Fuse box
2. Turn Learning switch to ON position (up).
3. Turn start-up key to ON position.
4. Wait for at least 10 seconds.
5. Turn Learning switch to OFF position (central).
Engine Program-
6. Turn start-up key to OFF position.
program- mation
mation switch
N.B. MC programmation cannot be carried out
position
if EX Doctor is connected with the machine.
60406991

Neutral position (OFF)

21599
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TS9-3-48

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.13.4 WITH PILOT CONTROL LEVERSIN NEUTRAL, THE AUTO-IDLE CANNOT BE OPERATED (ENGINE
SPEED IN AUTO-IDLE DOES NOT DECREASE ).

Check condition:
- Auto-Idle button actuated.
- Pilot control levers in neutral.
- Check on APC50 display if segment shows up.
- Disconnect fuses 25, 33 and 31.

Check line P6 Yes Replace SMC

Disconnect wires 58 and control unit.
connectors of 928.
pressure swit-
ches P5, P4, No
P6 to check if
vol-tage is 5
Von lines and To check ope-
pressure ration of pres-
switches. sure switches
P4 and P5 Yes Replace SMC
Yes check conti- control unit.
nuity of lines
Check on P4,
D1 and D2
P5, P6 if con-
and relay R16.
tacts are
opened. No
No

Replace diodes
Check opera- D1 and D2 relay
tion of hydraulic R16.
line.
Yes

Replace pres-
sure switch.

N.B. Reset fuses 25, 33 and 31.

60406991
21599

F9251
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TS9-3-49

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

F9201

Hydraulic pressure switch: closed with 3 ± 0.5 bar.

PRESSURE SWITCHES CONNECTION DIAGRAM

APC50
641
757

758

640

73

638
Controller 755
Box
766
759

760

74

58
59
60406991
21599

927
928

926

F9028
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TS9-3-50

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.13.5 ENGINE SPEEDS FAILED TO INCREASE DURING TRAVEL

Test condition:
- Engine speed control in maximum position.
- Check on APC50 display if segment shows up and disconnect fuses 25, 33 and 31.

If segment shows
up when press-
ing travel pedal,
pressure
switches are
operating.
Yes

Check if voltage
No Check line or
is 5 V on 87a of
control unit
relay R16 wire
failure.
59.

Yes
Check wire 73
on outlet 30 of No
relay R16. Replace relay.

Yes

Check opera-
tion of diodes No
D1 and D2 and Check line.
wires 73 and
75.
Yes

Check wires
758 and 757.

D
N.B. Reset fuses 25, 33 and 31. A

P
60406991
21599

F7401
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TS9-3-51

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

F9201

Hydraulic pressure switch: closed with 3 ± 0.5 bar

TRAVEL PRESSURE SWITCHES CONNECTION DIAGRAM

APC50
641
757

758

640

73

638
Controller 755
Box
766
759

760
60406991

74

58
59
21599

927
928

926

F9028
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TS9-3-52

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.14 DIESEL ENGINE FAILED TO START

Test condition:
- Starter does not run.
- Disconnect wires 524 and 505 on start-up relay.
- Start-up key in START position.

Check if alternator Yes Check if voltage is

indicator lights up. 24 V on wire 505
No
of start-up relay.
No
Check line and/or
replace start-up
switch.

Yes
Yes Check and/or re-
Check if voltage is place monitor.
0 V on monitor pin Check if voltage is
C14. 10 or 24 V on 87a Yes Check relay R5 or
of R5. negative 732.
No
No
Check if voltage is
24 V on pin 86 of No Check connec- Check line.
relay R1. tion wire 528.
No
Yes
Check if wire 217 Check for a nega-
Yes Check line from
Check if voltage is
Check if voltage is is negative on 87a tive on wire 524 Yes
No 24 V on alter- relay R2 to start-
0 ÷ 2 V on pin 85 of relay R2. point 30 relay R2.
nator D+. up relay.
of relay R1. No No
No Yes Yes
Yes

Check and/or re- Check wiring har- Check wiring har-

place relay R1. ness 527. ness. Replace relay R2.
Check if voltage is
24 V on start-up
relay contact
Check line and/or
Check and/or re-
replace start-up No wires 671 and
place alternator. 672.
relay.
Yes No
Check line.

Check electro-
magnet and star-
ter.
60406991
21599
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TS9-3-53

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15 TRANSMISSION CONTROL ELECTRONIC UNIT (APC 50) CHECKS

3.15.1GENERAL

The electronic control unit APC50 provides, by means of indicator lights and display, an aid to localise the
failure that can happen.
Different visualisations on the display can be obtained using the multifunction button.

2
1
1 - Display
2 - Multi function button
3 - Indicator, transmission control (yellow)
4 - Indicator, control unit failure (red)

3 4

The transmission control unit indicator light (3), yellow coloured provides the following functions:

- indicator light off means that the other speed gear can be selected;
- indicator light on with fixed light, means the machine is standing still;
- indicator light on with blinking light means the selected speed is not compatible with the speed of the
hydraulic travel motor; it occurs to change the speed gear.

The failure control unit light (4), red coloured, when switch on means a malfunction of control unit.
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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.2 DISPLAY

The visualization of the display is of a digital type with seven light segments. This visualization changes as a
function of the control selected (through the multi function button) as follows:
Note - As soon as power is provided to the machine, the display visualizes the real position of the transmission
gears and eventual error codes.

1st multi function button selection ⇒ the display visualizes the speed of the prop shaft, expressed in r.p.m.

2nd multi function button selection ⇒ the display visualizes the speed of the machine, expressed in km/h.

3rd multi function button selection ⇒ the display visualizes the input of the control signals.

4th multi function button selection ⇒ to return to the first selection on the display.

Graphical presentation of selection with multi function button

Normal display

Showing gear position and

error messages.

1st selection

Transmission speed
display

Expressed in r.p.m.

2nd selection

Speed display

Expressed in Km/h.

3rd selection
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Input signal
4th selection
monitoring
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TS9-3-55

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

Normal display: real position of the transmission gears and error messages

As soon as the power supply is provided to the machine, the display visualizes in the right segment, the real
position of the gears of the transmission.
If the gear shifting lever is in a position not corresponding to the real position of the gears of the transmission,
and the gear shifting is impossible, the display will visualize on the left segment (fixed light) the speed
requested and on the right segment (flashing light) the gear position really engaged.

Transmission in first gear Transmission in second gear

In case an error is occurring during the logic sequence of the transmission control, the display visualizes a
message (E) followed by the relevant error code (1. - 2 - 3 - 4 - 5 - 6 - 7 - 8).

Visualization of error code

E 1. ⇒ movement of gear shifting cylinder during the closing phase of the clutch.
E 2 ⇒ clutch remained open.
E 3 ⇒ clutch remained closed.
E 4 ⇒ gear shifting cylinder does not move.
E 5 ⇒ gear shifting cylinder moves, but it does not select the speed chosen.
E 6 ⇒ movement of the gear shifting cylinder is monitored during the initial phase of the shifting.
E 7 ⇒ movement of the shifting cylinder too fast.
E 8 ⇒ movement of the shifting cylinder during the opening phase of the clutch.

Speed of the prop shaft

With normal visualization on the display, pushing once the multi function button, it will display the revolving
speed of the prop shaft, shown in r.p.m..
If the display does not indicate any point, such a value must be multiplied by 10, to obtain the real value of
the rotation.
If the display visualizes a point on the side of the first digit, this value must be multiplied by 100, to obtain the
real value of the rotation.
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250 r.p.m. 1200 r.p.m.

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TS9-3-56

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

Speed of the machine

Pushing the multi function button the display will change the visualization to indicate the speed of the machine,
in km per hour. The figure indicating the speed will be accompanied by the showing of a point.

7 km/h 12 km/h

Input signals checking

Pushing once more the multi function button, the display will be preset for input signals monitoring.
The checking of the input signals occurs in the following manner:

Note: Start-up key in ON position, engine stopped.

Move the gearshift lever into automatic mode.

The display should show the segment, as illustrated.

Move the gearshift lever into second speed.

The display should show the segment, as illustrated.

Disengage the parking brake.

The display should show the segment, as illustrated.

Note: Engine running.

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Press the forward travel pedal.

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The display should show the segment, as illustrated.

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TS9-3-57

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

Press the reverse travel pedal.

The display should show the segment, as illustrated.

Start the machine, then move the gearshift lever from 1st ⇒ 2nd
or from 2nd ⇒ 1st speed.
The display should show the segment, as illustrated.

Select the “hare” function, then press the forward travel pedal.
The display should show the kick-down segment, as illustrated.

Note: Germany version.

The display will show the illustrated segment.

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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.3 OUTPUT MONITORING

If the multi function button on the display is pushed and held pushed at power up (key switch to ON position),
the APC 50 control unit perform the sequence of output monitoring.
In this condition the APC 50 control unit gives information about the status of the outputs on the display.
The possible states are:
G (Good);
S (Short circuit to ground);
O (Open load (output is not connected or has a short circuit to the positive + of the power supply).

The APC50 control unit tests each output sequentially, the left side of the display gives information about
which output is tested, the right side gives the status of the output.
It is not possible to drive when this test mode is switched on, and one can only leave it by switching off the
power supply turning to OFF the Key switch.

Output 1 is good

Output 2 has a short circuit to ground

Output 3 is not connected to the load or has a short circuit to the positive (+) of the power
supply

WARNING
For continuity test of transmission
solenoid valve, remove relay R10.

Each output is related to a specific output wire of control unit.

Pin on
Output Function
APC50
1 6 Clutch control (Solenoid valve C)
2 7 Not applicable
3 4 Parking brake control (Solenoid valve A)
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4 5 Gear shift cylinder control (Solenoid valve B)

5 9 Not applicable
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6 – Not applicable
7 – Not applicable
8 – Not applicable
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TS9-3-59

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

With machine efficient and correctly connected without failure, the visualisation in the sequence on the display
must be the following:

Output related to the clutch control output 1

– – –

Output related to the parking brake control output 3

Output related to the shift gear cylinder output 4

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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.4 PRINTING OF THE MEMORISED INFORMATION

The APC50 unit can be connected (through a serial connection) to an appropriate printer capable of providing
all the data, memorised by the unit itself, relative to various operating conditions performed.

These data can be summarised as follows:

• how long the machine has been operated;
• the quantity of gear shifting from 1st ⇒ 2nd or from 2nd ⇒ 1st made with the machine standing;
• the quantity of gear shifting from 1st ⇒ 2nd or from 2nd ⇒ 1st made with the control pedal no more than
1/2 way of its stroke;
• the quantity of gear shifting from 1st ⇒ 2nd or from 2nd ⇒ 1st made with the control pedal at full stroke;
• the times the APC50 unit has been disconnected, for whatever reason.

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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

V 1st speed 2nd speed 1st speed

+ 24 V

Value measured on
solenoid valve B (5)

0 t

V
+ 24 V

Value measured on
solenoid valve C (6)

0 t

V
Value measures on
+ 14/15 V terminals of micro-
switch for engaged
gear

0 t

P
- 35/40 bar

Pressure on gear
selection cylinder
line

0 t

P
- 35/40 bar
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Pressure on clutch
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control line

0 t
Typical diagram for transmission electrical and hdyraulic operation
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TS9-3-62

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.5 AUTOMATIC TRANSMISSION FAILED TO ENGAGE

Test condition:
- Check self-diagnosis APC50.

Check APC50
input signal from
gear switch on bar
code .

Yes

Check bar code Remove relay

from 1st ⇒ 2nd or Yes R10 and check
vice versa output signals of
Check and/or of synchro- solenoid valves,
replace wire. nizer SW. see page TS9-3-
58/59.
Yes No
No

Check line and Yes Check and/or re-

Check if voltage is No Check if voltage is solenoid valves place APC50.
14 V in outlet P15 14/15 V, see page A, B, C.
of APC50. TS9-3-61.
No
No Yes

Check line and/or

replace solenoid
Check and/or re- valve.
Check line and/or
place APC50.
replace SW syn-
chronizer.
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TS9-3-63

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

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TS9-3-64

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.6 2nd SPEED FAILED TO ENGAGE

Test condition:

Test condition:
- Check self-diagnosis APC50.

Check APC50
input signal from
gear switch on bar
code .

Yes

Check bar code Remove relay

from 1st ⇒ 2nd or Yes R10 and check
vice versa output signals of
Check and/or of synchro- solenoid valves,
replace wire. nizer SW. see page TS9-3-
58/59.
Yes No
No

Check line and Yes Check and/or re-

Check if voltage is No Check if voltage is solenoid valves place APC50.
14 V in outlet P15 14/15 V, see page A, B, C.
of APC50. TS9-3-61.
No
No Yes

Check line and/or

replace solenoid
Check and/or re- valve.
place APC50. Check line and/or
replace SW syn-
chronizer.
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TS9-3-65

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

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TS9-3-66

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.7 AUTOMATIC TRANSMISSION FAILED TO ENGAGE

Test condition:
- First and second manual speeds operating.
- Shift transmission lever to automatic.
- Switch in position (hare).

Check on
APC50 display
if segment
shows up .
Check on Yes
APC50 dis-
play if the
No
revolution
number is
Replace gear
shown.
switch.
No
No

Check line of
Check on dash- pin 19 wire 671
Check APC50
Yes board if the APC50 on gear
Yes Check gear
connection speedometer is switch.
switch.
line. operating. Yes
No
No

Check and/or Check and/or

No Check if sen- replace wire.
Replace replace APC50.
sor is operating.
sensor.
Yes

Check line from

sensor to rota-
ting joint and to
APC50.

WARNING
Only Germany version includes a
connector to be connected next to
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APC50 control unit. Check operation

of line 750 with 751.
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TS9-3-67

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.15.8 OPERATION DIAGNOSIS

Check if voltage is
Check fuse 31 Yes 24 v on wires Yes Control unit failure:
and APC50 connec- +741 and -761; replace.
tor. +741 and -748;
+741 and -762.
No
No

Replace fuse and

connector hook. Check wiring.
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TS9-3-68

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3 . 1 6 TEST HARNESSES KIT 75301702

3.16.1TEST HARNESSES

A) two pins wiring harness to check solenoid valves.

B) three pins wiring harness to check angle sensor.

C) three pins wiring harness to check brake oil pressure.

D) four pins wiring harness to check Step Motor.

E) four pins wiring harness to check rear light rotating joint.

F) six pins wiring harness to check rotating joint.

G) six pins wiring harness to check steering column.

H) eight pins wiring harness to check steering column.

3.16.2 TEST HARNESS

A) TWO PINS WIRING HARNESS TO CHECK SOLENOID VALVES

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F9074

1 2
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TS9-3-69

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.3TEST HARNESS

B) THREE PINS WIRING HARNESS TO CHECK ANGLE SENSOR

F9029
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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.4TEST HARNESS

C) THREE PINS WIRING HARNESS TO CHECK BRAKE OIL PRESSURE

F9293

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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.4TEST HARNESS

D) FOUR PINS WIRING HARNESS TO CHECK STEP MOTOR

F9030
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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.5TEST HARNESS

E) FOUR PINS WIRING HARNESS REAR LIGHT ROTATING JOINT

F9075

4 3 2 1

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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.6 TEST HARNESS

F) SIX PINS WIRING HARNESS TO CHECK ROTATING JOINT

F9076

6 5 4 3 2 1
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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.7 TEST HARNESS

G) SIX PINS WIRING HARNESS TO CHECK STEERING COLUMN

F9291
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ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

3.16.9 TEST HARNESS

H) EIGHT PINS WIRING HARNESS TO CHECK STEERING COLUMN

F9292
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TS9-3-76

ELECTRICAL SYSTEM TROUBLESHOOTING EX135W

NOTES:

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INDEX EX135W -10- 1

SECTION 10 OPERATIONAL PERFORMANCE TEST

INDEX

Group 1 - INTRODUCTION...................................................................................... PT10-1-1

1.1 General information for testing of the machine

Group 2 - PERFORMANCE STANDARD ................................................................. PT10-2-1

2.1 Table of excavator performance standard

2.2 Table of hydraulic components performance standard
2.3 Main pump P-Q diagram
2.4 Secondary pump P-Q diagram

Group 3 - PREPARATION FOR PERFORMANCE TEST ........................................ PT11-3-1

3.1 Introduction

Group 4 - EXCAVATOR PEFORMANCE TEST ........................................................ PT10-4-1

4.1 Engine performance

4.2 Swing performance
4.3 Front attachment performance
4.4 Control lever performance
4.5 Lift/swing performance
4.6 Steering
4.7 Brakes system
4.8 Transmission
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Group 5 - COMPONENTS PERFORMANCE TEST ................................................ PT10-5-1

5.1 Pilot pressure relief valve

5.2 Pressure relief valves
5.3 Flow control priority valve
5.4 Transmission drive shaft
5.5 Hydraulic pumps
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PT10-1-1

INTRODUCTION EX135W

1. INTRODUCTION

1.1 GENERAL INFORMATION FOR

TESTING OF THE MACHINE

(1) Know the system

Study this Service Manual to know how the
individual components work and what their
function is in the over-all system.
Keep-up with the latest service information.
Read and file in a handy place. This
information may give a response about the
causes and the remedy for future problems.

(2) Ask the operator

Question the operator as to how the machine
acted when the failure was detected. Also
find out if any improper service was
performed.
Ask how the machine has being used and
when it was serviced. Many problems can
be traced to poor maintenance or abuse.

(3) Operate the machine

Get on the machine and operate it. Don’t rely
completely on the operator’s story; check it
yourself.
Perform a complete visual check of the unit
to detect any sign of failures or malfunctions.
Check carefully all the components for cracks
in the weldings, loose bolts, broken fixtures,
worn or leaking pipings, etc.

(4) Test the machine

Proceed with the performance tests, following
the instructions and the data provided by this
Manual.
Record all signs of troubles encountered
during the operation.
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TS 10-1-2

INTRODUCTION EX135W

NOTES:

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PT10-2-1

PERFORMANCE STANDARD EX135W

2. PERFORMANCE STANDARD

2.1 TABLE OF EXCAVATOR PERFORMANCE STANDARD

Refer to paragraph PT11-4 for the test procedure * Hydraulic oil temperature 50 ± 5°C (122 ± 9°F)

ENGINE SPEED rpm

Start idle 950 ± 50
Auto idle 1250 ± 100
Hydraulic oil warm up OPTICAL INDICATOR ON
Mode P 2080 ± 100
Mode E 1850 ± 100
Mode I 950 ± 50
Travel (mode P engaged) 2290 ± 90

SWING SPEED sec/3 rpm 20,5 ± 1,0 No difference between

both direction

SWING FUNCTION
DRIFT CHECK mm/180° ≤ 900

PARKING BRAKE/SWING
LEAKAGE TEST mm/5 min 0

SWING BEARING PLAY ≤ 2 mm

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PT10-2-2

PERFORMANCE STANDARD EX135W

SERIAL N. 0051 ➔ NOTES

ITEMS

3.1 CYLINDER CYCLE TIME sec

Boom Lift 3.5 ± 0.3
(Monobloc version) Drop 3.5 ± 0.3
Boom Lift 3.9 ± 0.3
(Triple articulation version) Drop 3.5 ± 0.3
Arm Roll-in 4.2 ± 0.5
Roll-out 3.0 ± 0.5
Bucket Roll-in 3.4 ± 0.5
Roll-out 2.1 ± 0.5
Positioner Roll-in 4.9 ± 0.5
(Triple articulation version) Roll-out 3.9 ± 0.3
3.2 DRIFT
CHECK mm/5 min
Boom cylinder ≤ 25
Positioner cylinder (Triple articulation version) ≤ 40
Arm cylinder ≤ 45
Bucket cylinder ≤ 25
From total drop Monobloc version ≤ 500
Triple articulation ≤ 500

4.1 CONTROL LEVER

OPERATING FORCE kgf
Boom & arm ≤ 1.7
Bucket & swing ≤ 1.7
4.2 CONTROL LEVER STROKE mm
Boom & arm 75 ± 10
Bucket & swing 75 ± 10

5.1 COMBINED BOOM RAISE/

SWING FUNCTION CHECK mm

Height of bucket teeth/ground ≤ 5600

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PT10-2-3

PERFORMANCE STANDARD EX135W

SERIAL N. 0051 ➔ NOTE

ITEMS

6.1 STEERING PUMP PRESSURE

CHECK bar 145 ± 10 Modo P

7.1 PARKING BRAKE

CHECK giri 0

7.2 BRAKE VALVE PRESSURE

TEST bar

SERVICE condition 70 ± 5

WORK condition 70 ± 5

7.3 ACCUMULATOR PRESSURE Preload pressure bar 50 ± 10

CHECK Maximum pressure bar 135 ± 15

8.1 TRANSMISSION PRESSURE

CHECK bar > 35
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PT10-2-4

PERFORMANCE STANDARD EX135W

2.2 TABLE OF HYDRAULIC COMPONENTS PERFORMANCE STANDARD

PILOT CONTROL
SYSTEM PRESSURE bar 40 ± 9

FRONT ATTACHMENT AND

TRAVEL OVERPRESSURE bar

Main circuit
Measurement on main
overpressure 315 ± 15 pump.

Front attachment Load sensing Measurement on main

relief valve 285 ± 15 pump.

Measurement on main
∆P 20 +- 10 pump.
Measurement on main
Neutral 40 ± 8 pump.
Measurement on main
Travel Forward 315 ± 15 pump.
Measurement on main
Revers 315 ± 15 pump.

BLADE - OUTRIGGER Secondary pump circuit

OVERPRESSURE bar 330 measurement.

SWING OVERPRESSURE bar 310 ± 15 Secondary pump circuit

measurement.

CHECK OF FLOW CONTROL

+3
PRIORITY VALVE l/min 12 - 0

TRANSMISSION
DRIVE SHAFT SPEED rpmi/min

STANDARD version 1st speed gear 190 - 210 TORTOISE pos.

2nd speed gear 2100 - 2284 HARE pos.

(with pressure 190 to
200 bar)

GERMANY version 1st speed gear 360 - 380 HARE pos.

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MAIN PUMP FLOW MAX l/min 191

MIN l/min 30 at 50 bar and at 2100 rpm

SECONDARY PUMP FLOW l/min 58 ± 1 at 25 bar and at 2100 rpm

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PT10-2-5

PERFORMANCE STANDARD EX135W

2.3 MAIN PUMP P-Q DIAGRAM

p [bar] -->
300

(*) Q = 155 ÷ 166 l/min

200
100

Q = 191 l/min
a P = 50 bar

0 50 100 150 200

Q [l/min] -->
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Notes: - Main pump type A11V095 LRCS indicative diagram

- (*) Supplier standard values
Test condition:
- Hydraulic oil temperature = 50 ± 5°C (122 ± 9°F)
- Pump speed = 2100 rpm
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PT10-2-6

PERFORMANCE STANDARD EX135W

2.4 SECONDARY PUMP P-Q DIAGRAM

+1
(*) P1 = 150 bar Q1 = 46 - 1.5 l/min
300

+1
(*) P2 = 250 bar Q2 = 25 - 1.5 l/min

P2
200

P1
100

Q = 57±1 l/min
a P = 25 bar

0 30 60
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Q [l/min] -->

Notes: - Secondary pump type A10V028 DFLR indicative diagram

- (*) Supplier standard values
Test condition:
- Hydraulic oil temperature = 50 ± 5°C (122 ± 9°F)
- Pump speed = 2100 rpm
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PT10-3-1

PREPARATION FOR PERFORMANCE TEST EX135W

3. PREPARATION FOR PERFORMANCE TEST

3.1 INTRODUCTION

Performance tests are used to check:

1 OPERATIONAL PERFORMANCE OF A NEW

MACHINE
When a new machine is delivered in the form of a
knocked-down unit, assemble it and perform the
test to verify that the operational performances meet
FIAT-HITACHI standards.

Work
2 OPERATIONAL PERFORMANCE OF A conditions
WORKING MACHINE
In time, the machine operational performance
deteriorates, so that periodical service operations Operating
time Maintenance
are required to restore it to its original level. conditions

3 OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After a machine is repaired or serviced, it must be
tested to confirm that its operational performance
has been restored by the repair and/or the service
operations done.

3.1.2 GLOSSARY

1 STANDARD
Specifications applied to brand-new machines,
components and parts.
STANDARD
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PT10-3-2

PREPARATION FOR PERFORMANCE TEST EX135W

3.1.3 PREPARATION FOR PERFORMANCE TEST

Observe the following rules to execute the

performance tests accurately and safely.

1 THE MACHINE.
Repair any defect and damage found, such
as oil or coolant leakages, loose bolts, cracks
and so on, before starting the test.

2 TEST AREA

(1) Select a hard, flat surface.

(2) Provide enough space to allow the machine
to run straight for more than 50 m (164 ft) and
to make a full swing with the front attachment
extended.
(3) If necessary, rop-off the test area and place
signboards to keep unauthorized personnel
away.

3 PRECAUTIONS

(1) Before starting the tests, establish the signals

to be emplyed to communicate with co-
workers. Once the test is in progress, make
sure that only the established signals are used,
and that the rules are strictly followed.
(2) Operate the machine carefully and always give
first priority to safety.
(3) During the test, always take care to avoid
accidents due to landslides or contact with
electric power lines.
(4) Avoid polluting the machine and the
environment with oil spillages. Use adequate
containers to contain fluid leakages. Pay
special attention to this problem when
removing hydraulic pipings.

4 MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate in advance the

instruments used during the tests, to obtain
correct data.
(2) Perform the tests under the exact prescribed
conditions for each test item.
(3) Repeat the same test to confirm that the data
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obtained are repeatable. Use mean values of

measures, if necessary.
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PT10-4-1

EXCAVATOR PERFORMANCE TEST EX135W

4. EXCAVATOR PEFORMANCE TEST

H
2
4.1 ENGINE PERFORMANCE C F
E
4.1.1 ENGINE SPEED A/I CONTROL BUTTON

With the key-start switch on the ON position, press the E

A/I
A/I control button (1) to bring the engine speed to
automatic preset idle.
This speed is attained in approximately 4 seconds,
provided that all controls are in the neutral position,
with consequent fuel savings.

When the A/I control button (1) is pressed, the yellow CHECK
indicator light (2) on the monitor panel will illuminate.
2
Press the button again to disable this function. The 1
indicator light will go off at the same time. OFF

1 A/I

F5348
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PT10-4-2

EXCAVATOR PERFORMANCE TEST EX135W

4.2 SWING PERFORMANCE

4.2.1 SWING SPEED

Measure the time required to swing three complete

turns.

Preparation:

(1) Check the lubrication of the swing gear and

swing bearing.
(2) Place the machine on flat, solid ground with
ample space for swinging. Do not attempt this
test on a slope.
(3) With the arm rolled-out and the bucket rolled-
in, hold the bucket so that the height of the
bucket pin is the same as the boom foot pin.
The bucket must be empty.
(4) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Operate the swing control lever fully.

(3) Measure the time required to swing three com-
plete turns in one direction.
(4) Operate the swing control lever fully in the
opposite direction and measure the time
required to swing three complete turns.
(5) Repeat steps (3) and (4) three times and work-
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-3

EXCAVATOR PERFORMANCE TEST EX135W

4.2.2 SWING FUNCTION DRIFT CHECK

Measure the swing drift on the bearing outer

circumference, when stopping, after a 180° full-speed
swing.

Preparation:

(1) Check the lubrication of the swing gear and

swing bearing.
(2) Place the machine on flat, solid ground with
ample space for swinging. Do not attempt this
test on a slope.
(3) With the arm rolled-out and the bucket rolled-
in, hold the bucket so that the height of the
bucket pin is the same as the boom foot pin.
The bucket must be empty.
(4) Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
(5) Swing the upperstructure 180°.
(6) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Operate the swing control lever fully and return

it to the neutral position when the mark on the
upperstructure aligns with that on the track fra-
me, after swinging 180°.
(3) Measure the deviation between the two marks. Measure the deviation

(4) Align the marks again, swing 180°, then test the
opposite direction.
(5) Repeat steps (3) and (4) three times and work-
out the average values.

Mark on the
Evaluation: Mark on the track frame
bearing

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-4

EXCAVATOR PERFORMANCE TEST EX135W

4.2.3 PARKING BRAKE/SWING LEAKAGE TEST

Measure the upperstructure drift when a load is applied

to the bucket on a slope.

Preparation:

(1) Check the lubrication of the swing gear and swing

bearing.
(2) The face of the test slope shall be even, with a
10° gradient.
(3) With the arm rolled-out and the bucket rolled-in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin. Apply a
rated load (W) to the bucket.
W=M3 x 1.5
3
where: M = bucket capacity (cum)
1.5 = sand specific gravity
(4) Swing the upperstructure to a position 90° to the
slope. Make two chalk marks: one on the swing
bearing, and one directly below on the track fra-
me.
(5) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Keep the engine a low-idle. After 5 minutes,

measure the deviation between the two marks.
Measure the deviation
(2) Perform the test on both right and left swing
directions.
(3) Perform the tests three times in each direction
and work-out the average values.

Evaluation:
Mark on the
Refer to Group 2 - PERFORMANCE STANDARD. Mark on the track frame
bearing
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PT10-4-5

EXCAVATOR PERFORMANCE TEST EX135W

4.2.4 SWING BEARING PLAY

Measure the swing bearing play using a dial gauge to

check the wear of bearing races and balls.

Preparation:

(1) Check that the bearing mounting bolts are

tightened at the prescribed torque.
(2) Check the lubrication of the swing bearing and
that the bearing rotation is smooth and
noiseless.
(3) Install a dial gauge on the track frame, as
shown, using a magnetic base.
(4) Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
(5) Position the dial gauge so that its needle point
touches the bottom face of the bearing outer
race.
(6) The bucket must be empty.

Measurement:

(1) With the arm rolled-out and the bucket rolled-

in, hold the bucket so that the height of the
bucket pin is the same as the boom foot pin.
Record the dial gauge reading (h1).
(2) Lower the bucket to the ground and use it to
raise the front idlers 0.5 m (2 ft). Record the
dial gauge reading (h2).
(3) Draw-out the bearing play (H) from these data
(h1 and h2) as follows:

H=h2-h1

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

Mesurement: (h1) Measurement: (h2)

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PT10-4-6

EXCAVATOR PERFORMANCE TEST EX135W

4.3 FRONT ATTACHMENT PERFORMANCE

4.3.1 HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the cylinder.

MONOBLOC VERSION
(Arm, bucket and boom).
TRIPLE ARTICULATION VERSION
(Arm, bucket, boom and positioner). Fig. 1

Preparation and Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Boom cylinder:

Preparation:
Fully roll-out the arm, roll-in the bucket (empty).
Lower the bucket to the ground (as shown in fig.
1), or raise the boom to its stroke-end. Place the
control lever in neutral. Fig. 2
Measurement:
To measure the time taken to raise the boom,
pull-back fully the control lever, until the boom
cylinder reaches its stroke-end. To measure the
time taken to lower the boom, push the control
lever fully forward, until just before the bucket
makes contact with the ground.
(3) Positioning cylinder:
Preparation:
Extend completely the dipping, bucket and
positioning cylinders. Position the bucket about
0.5 m (2 ft) from the ground (as shown in fig. 2),
using the boom cylinders.
Measurement:
Actuate the control pedal to full stroke and retract Fig. 3
completely the positioning cylinder. Measure the
time required by each retraction and extension
operation.
(4) Arm/bucket cylinders:
Preparation of dipper cylinder:
Position the boom and arm so that the bucket
bottom clears the ground by at least 0.5 m (2ft)
(as shown in fig. 3).
Preparation of the bucket cylinder:
The empty bucket should be positioned at
midstroke beetween roll-in and roll-out, so that
the side plate edges are vertical to the ground.
60406991

Measurement:
To measure the time taken to fully roll-out or roll-
in the arm or bucket, fully push or pull the control
21599

levers and record the time taken by each roll-in

and/or roll-out operation.
(5) Perform the tests three times in each direction
and work-out the average values.

Evaluation:
Refer to Group 2 - PERFORMANCE STANDARD.
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PT10-4-7

EXCAVATOR PERFORMANCE TEST EX135W

4.3.2 DRIFT TEST

Measure the drift of the front attachment with bucket

loaded.
The drift can be caused by oil leakages in the control
valve and/or cylinders.

Note: When testing the drift just after the replacement

of a cylinder, slowly operate each cylinder to its
stroke-end to bleed all the air.

Preparation:

(1) Fully load the bucket. In lieu of a bucket load, it

is possible to use a load (W) as follows:
W=M3 x 1.5
3
where: M = bucket capacity (cum)
1.5 = sand specific gravity.
(2) Position the arm cylinder and positioning
cylinder (triple articulation version) with the rod
20-30 mm (3/4 - 1 1/4 in) from fully retracted
stroke-end.
(3) Position the buket cylinder with the rod 20-30
mm (3/4 - 1 1/4 in) from fully extended stroke-
end. EQUAL ELEVATION
(4) With the arm rolled-out and the bucket rolled-
in, hold the bucket so that the height of the
bucket pin is the same as the boom foot pin.
(5) Keep the hydraulic oil temperature at 50 ± 5°C DOWN BUCKET
(122 ± 9°F).

Measurement:

(1) Stop the engine.

(2) After 5 minutes, measure the deviation in the
positions of the bottom of the bucket, as well as
the boom, arm and bucket cylinder.
(3) Perform the tests three times and work-out the
average values.

BOOM AND BUCKET CYLINDER RETRACTION ARM AND POSITIONING CYLINDERS EXTENSION

mark mark

mark
21599 60406991

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-8

EXCAVATOR PERFORMANCE TEST EX135W

4.4 CONTROL LEVER PERFORMANCE

4.4.1 CONTROL LEVER OPERATING FORCE

Use a spring scale to measure the maximum

resistance of each control lever at the middle of the
grip.

Preparation:

(1) Start the engine.

(2) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
(1) Select the following switch position:

Auto-idle switch

OFF

(2) Operate each boom, arm, bucket lever and

swing lever at full stroke, measuring each
maximum operating force.

(3) Repeat step (2) three times and work-out the

average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

4.4.2 CONTROL LEVER STROKE

Measure each lever stroke at the lever top using a
ruler.

Note: When the lever has a play, take half of this

value and add it to the measured stroke.

Preparation:

(1) Start the engine.

(2) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Stop the engine.

(2) Measure each lever stroke at the lever top from
60406991

neutral to stroke-end, using a ruler as

reference.
21599

(3) Repeat step (2) three times and work-out the

average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-9

EXCAVATOR PERFORMANCE TEST EX135W

4.5 LIFT/SWING PERFORMANCE

4.5.1 COMBINED BOOM RAISE/SWING FUNCTION

CHECK

Check the boom and swing movements and speeds

while operating both functions simultaneously.

Preparation:

(1) Start the engine and run it at fast-idle. Operate

the boom raise function and check that the
cylinder movement is smooth, without any
hesitation.
(2) With the arm fully extended and the bucket fully
rolled-in, lower the bucket (empty) to the ground.
(3) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Raise the boom and swing simultaneously, both

at full stroke.
(3) After the upperstructure has rotated 90°, release
the control levers to stop both functions. Measure
the time required to swing 90° and the height of
the bucket teeth from the ground.
(4) Repeat steps (2) and (3) three times and work-
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-10

EXCAVATOR PERFORMANCE TEST EX135W

4.6 STEERING

4.6.1 STEERING PUMP PRESSURE CHECK

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil reservoir
removing the bleeding plug.
(3) Disconnect the hose from the steering pump
and steering valve and install a 0 to 200 bar
pressure gauge.
(4) Start the engine and check for oil leakages.
(5) Keep the oil temperature at 50 ± 5°C (122 ±
9°F).

Measurement:

(1) Select the following position:

Auto idle switch

OFF
Pressure gauge

(2) Turn the steering wheel right and left a few

times.
(3) Measure the pressure value of the oil on the
pressure gauge.
(4) Repeat the operation three times and work out Steering valve
an average value.

Steering pump
Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-11

EXCAVATOR PERFORMANCE TEST EX135W

4.7 BRAKES SYSTEM

4.7.1 PARKING BRAKE CHECK

Measure the parking (negative) brake function on

a slope.

Warning:
Be sure to perform this parking brake test, as it is
important for safety.

Preparation:

(1) Park the machine on a smooth and dried

slope with a gradient of 10°.
(2) Keep the hydraulic oil temperature at 50 ±
5°C (122 ± 9°F).

Measurement:

Turn the brake switch on to insert the parking

(negative) brake.

Evaluation:

Keep the machine parked on the slope confirm

that the brake des not slip.

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-4-12

EXCAVATOR PERFORMANCE TEST EX135W

4.7.2 BRAKE VALVE PRESSURE TEST

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil reservoir
removing the bleeding plug.
(3) Connect two pressure gauge with 0 to 200 bar
scale between T1 and T2 hoses connecting brake
valve and rotary joint as shown.

Measurement for SERVICE condition:

(1) Start the engine and operate the brakes a few

times and check for leakages of oil from the
connections.
(2) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).
(3) Select the following position:

Auto idle switch

OFF

(4) Measure the pressure on the pressure gauge.

(5) Repeat the operation three or four times and
work out an average value.

Measurement for WORK condition:

(1) Start the engine, push the work brake switch on

central panel and check for leakages oil from
the connections.
(2) Keep the temperature of hydraulic oil at 50 ±
T2
5°C (122 ± 9°F). T1
(3) Select the following position:

Auto idle switch

OFF To
Pump
rotary
joint

(4) Measure the pressure on the both pressure F11165

gauges.
(5) Repeat the operation three or four times and Pilot filter
work out an average value.
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PT10-4-13

EXCAVATOR PERFORMANCE TEST EX135W

4.7.3 ACCUMULATORS PRESSURE CHECK

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil reservoir
removing the bleeding plug.
(3) Connect a 0 to 200 bar pressure gauge
between the accumulator and the brake val-
ve.
(4) Start the engine and brake a few times to cau-
se the automatic charge and check for oil
leakages from the connections.
(5) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

(1) Select the following position:

Pressure gauge

Auto idle switch

Accumulators
OFF
F11166

(2) The accumulators are pre-charged with

pressurized nitrogen. To check the gas
pressure in the accumulator, use the
appropriate tooling with pressure gauge while
the accumulators are discharged of the
hydraulic oil. To check the pressure of the gas
through the pressure of the oil, connect a
pressure gauge to the accumulator (on the
connecting pipe), charge the accumulators
and, with engine OFF, discharge the
accumulators actuating the brakes several
times or loosening a connection. The pressure
will drop slowly to a certain value than drops
to zero suddenly. The last reading corresponds
to the pre-charge pressure of the gas.
The test must be repeated on all three
accumulators.

Evaluation:
Refer to Group 2 - PERFORMANCE STANDARD.
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PT10-4-14

EXCAVATOR PERFORMANCE TEST EX135W

4.8 TRANSMISSION

4.8.1 TRANSMISSION PRESSURE CHECK

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil reservoir
removing the bleeding plug.
(3) Connect a 0 to 100 bar pressure gauge (A) to
hydraulic oil supply input of shifting gear
cylinder, as shown.
(4) Start the engine and check for oil leakages
from the connections.
(5) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

(1) With speed control lever select, alternatively,

high and low speed.

Auto idle switch

OFF

(2) With low speed engaged: the pressure gauge

should read more than 35 bar and with high
speed engaged the pressure gauge should
read 0 bar.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD. 60406991

A
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PT10-5-1

COMPONENTS PERFORMANCE TEST EX135W

5. COMPONENTS PERFORMANCE TEST

5.1 PILOT PRESSURE RELIEF VALVE

5.1.1 PILOT PRESSURE

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil reservoir by
removeing the air breather cap.
(3) Install a pressure gauge with a 0 to 60 bar sca-
le, on quick T connection, as shown.
(4) Start the engine and check for oil leakages from
the connections.
(5) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Select the following switch position:

Rotary joint
Auto-idle switch

OFF

OFF
Accumulator

(2) Measure the pilot pressure in I-mode (slow-idle).

(3) Perform the tests three times and work-out the
average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

Pressure
gauge

Utility solenoid
valves assembly

Priority
valve
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PT10-5-2

COMPONENTS PERFORMANCE TEST EX135W

5.1.2 SETTING OF THE PRESSURE RELIEF VALVE

INCLUDED IN THE UTILITY SOLENOID VALVE
ASSEMBLY

Preparation:
1
(1) Unscrew the plug (1).
(2) Adjust the pressure relief valve by acting directly
on the screw (2) and checking the pilot pressure
on pressure gauge connected as per procedure
1.1.

Pressure relief valve

F7310

Utility solenoid
valves assembly
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PT10-5-3

COMPONENTS PERFORMANCE TEST EX135W

5.2 PRESSURE RELIEF VALVES

5.2.1 MEASUREMENT OF FRONT ATTACHMENT

AND TRAVEL OVERPRESSURE
(Main pump circuit)

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil tank removing
the bleeding plug. B
(3) Connect a 0 to 400 bar pressure gauge (A) to
the test port M (B) of the main pump as
illustrated.
(4) Start the engine and check for leakages from
the connections.
(5) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

(1) Select the following position:

Auto idle switch A

OFF

(2) Slowly actuate one of control function: raising,

dipper stick, bucket and positioning (triple
articulation version) to full stroke and measure
the pressure.
(3) Actuate the travel function and at the same time,
stop the undercarriage applying the brake pedal,
than measure the pressure.
(4) Repeat steps (2) and (3) three times and work
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

60406991
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PT10-5-4

COMPONENTS PERFORMANCE TEST EX135W

Front attachment and travel overpressure

adjustment

(1) Climb up upperstructure. B A

(2) Adjust the pressure by acting on cut off valve A
on control valve as shown.
(3) Screwing/unscrewing the cut off valve A to obtain
the correct setting, measurable by means of a
pressure gauge connected as per procedure 2.1.
Pay attention during the lock nut tightening of
the cut off valve (A).
Use two 17 mm spanner wrenches for this
operation.
The valve body must be screwed to the control
valve body with a maximum torque tightening of
25 Nm.

Note: If it is not possible to obtain the required value,

check the maximum setting of main relief val-
ve (B).
In order to check the main relief valve (B)
setting, it needs to increase the cut off valve
(A) setting, by screwing completely the
adjusting screw.
Check the main relief valve (B) setting should
be 320 +5 - 0 bar by means of a pressure gauge
connetected as per procedure 2.1.

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PT10-5-5

COMPONENTS PERFORMANCE TEST EX135W

5.2.2 MEASUREMENT OF BLADE-OUTRIGGER

OVERPRESSURE
(Secondary pump circuit)

Preparation:

(1) Stop the engine. B

(2) Bleed the air from the hydraulic oil tank removing
the bleeding plug.
(3) Connect a 0 to 400 bar pressure gauge (A) to
the test port (B) on control valve as shown.
(4) Start the engine and check for leakages from
the connections.
(5) Keep the temperature of the hydraulic oil at 50
± 5°C (122 ± 9°F).

A
Measurement:

(1) Select the following position:

Auto idle switch

OFF

(2) By means of pilot valve, slowly actuate the blade

or the outriggers.
(3) Read the pressure on the pressure gauge.
(4) Repeat steps (2) and (3) three times and work
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-5-6

COMPONENTS PERFORMANCE TEST EX135W

Blade-Outrigger overpressure adjustment

(1) Remove cap from locking nut of cut off valve.

Note: Be care during the cap removal as a seal ring is

installed.

(2) Loosen the lock nut.

(3) Adjust pressure by means of adjusting screw (C)

with a socket wrench, as shown.

Note: Turn clockwise = to increase pressure

Turn counterclockwise = to decrease pressure

(4) By acting the adjusting screw, obtain the required

value, as read on pressure gauge connected as per
procedure 2.2.

Cut off valve

Seal ring
Cap Lock nut

C 60406991
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PT10-5-7

COMPONENTS PERFORMANCE TEST EX135W

5.2.3 MEASUREMENT OF SWING OVERPRESSURE

Preparation:

(1) Stop the engine.

(2) Bleed the air from the hydraulic oil tank removing
the bleeding plug.
(3) Connect a 0 to 400 bar pressure gauge (A) to B
the test port (B) of the control valve as shown.
(4) Start the engine and check for leakages from
the connections.
(5) Keep the temperature of the hydraulic oil at 50 ±
5°C (122 ± 9°F).

Measurement:

(1) Select the following position: A

Auto idle switch

OFF

(2) By means of swing pilot valve, set the bucket

against a solid object.
(3) Insist to hold the swing pilot valve at fully stroke
end. At the same time read the pressure when
the valve releasing.
(4) Repeat steps (2) and (3) three times and work
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-5-8

COMPONENTS PERFORMANCE TEST EX135W

Swing overpressure valve adjustment

Note: In order to perform the swing overpressure valve

setting, it needs first to increase the setting level
of cut off valve of secondary pump controller of
about 1 turn.
From control valve
(1) Disconnect the pilot hoses after position marking
to avoid inversion during reassemble. Pilot hoses
(2) Install plugs to avoid oil spilling.
(3) Loosen lock nut (3), then fully close the bush (4) to
simulate the pilot pressure.
(4) Loosen lock nut (1), then turn the ring nut (2) until
to reach the maximum pressure (320 bar at valve
releasing) measurable by pressure gauge
connected as per procedure 2.3.
(5) Unscrew the bush (4) until to reach the braking
pressure (180 bar at valve releasing), measurable
by pressure gauge connected as per procedure 2.3,
making care to maintain the ring nut (2) locked.
(6) Tighten the lock nut (3), then reconnect the pilot
hoses to the relate valves.

Notes: • For further accuracy of adjustment, recheck

the pressure of the valve releasing.

• Repeat the procedure shown in paragraph

1 2 3 4

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PT10-5-9

COMPONENTS PERFORMANCE TEST EX135W

Secondary pump relief valve adjustement

To check the setting of secondary pump relief valve (D) D

(set at 330 bar), it needs:

(1) Connect the pressure gauge as per procedure 2.2.

(2) Increase the setting of cut off valve by screwing the
adjustment screw of one turn.
(3) Carry out the measurement as per procedure 2.2
and check the secondary pump relief pressure
setting should be 330 bar.
(4) After checking or setting of the secondary pump
relief valve, restore the setting of the secondary
pump cut off valve at 310 bar, as per procedure
2.2.1.
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PT10-5-10

COMPONENTS PERFORMANCE TEST EX135W

5.3 FLOW CONTROL PRIORITY VALVE

5.3.1 CHECK OF FLOW CONTROL PRIORITY VALVE

Check of the hydraulic oil flow of the flow control priority

valve.

Preparation:

(1) Keep the temperature of the hydraulic oil at 50 ±

5°C (122 ± 9°F).
(2) Bleed the air from the hydraulic oil tank removing
the bleeding plug.
(3) Disconnect the hose (A) from tank side, then placed
it into a proper graduated container (B).
(4) Install a threaded plug on the tank connection.
(5) Provide with a stopwatch. A

Measurement:

(1) Start the engine.

(2) Select the following position B

Auto idle switch

OFF

(3) By means of graduated container (B) and a

stopwatch, check the oil flow of the valve (C),
measuring the quantity of oil (in litres) that spill out
the hose within a period of one minute.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

To rotary joint To accumulator

A
C
60406991
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PT10-5-11

COMPONENTS PERFORMANCE TEST EX135W

5.4 TRANSMISSION DRIVE SHAFT

5.4.1 TRANSMISSION DRIVE SHAFT SPEED

Check the revolution speed of the transmission drive

shaft.

Preparation:

(1) Disconnect the lower flexible hose from hydraulic

pump.
Install a pressure nipple using a T union.
(2) Install two transducers (calibrated at 600 bar) to A
the point (A) and (B) as shown in Fig. 1.
(3) Connect the harness transducers to the digital
gauge for pressures detection.
(4) Apply a reflective label on the drive shaft in order
to measure the drive shaft revolution speed
with an electronic digital tachometer.
(5) Lift the excavator of the ground using the B
outrigger, blade and front attachment; then lock
the front axle.

First speed measurement - STANDARD version:

(1) Set the controls as follows:

- Engine speed to maximum
- Set slow speed position (tortoise)
- Select first speed gear Fig. 1
- Operate the travel pilot valve (pedal) to forward
stroke-end.
(2) Stabilize the travel speed with the hydraulic oil
temperature at 50 ± 5°C (122 ± 9°F).
Measure the drive shaft revolution speed using
an electronic digital tachometer.
(3) Check the ∆P value = 21 –0
+1
bar by means of digital
pressure gauge, computing it by the difference
between points (A) and (B) pressure readings.

WARNING

Pay the utmost care to the wheel and drive shaft

revolutions in order to avoid injury to the people.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

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PT10-5-12

COMPONENTS PERFORMANCE TEST EX135W

■ If the ∆p pressure value obtained is out of

tolerance expected ∆p = 21 +- 10 bar, should nedd
to remove the seal of lead and operate on the
screw located on pump controller of main pump.
(Fig. 2).

Fig. 2

■ In case the ∆p pressure value is within the

tolerance limit but the drive shaft revolution speed
is out of specification values, should need to set
the control valve to adjust the travel motor speed.
Loosen the lock cap and operate on the related
adjusting screw of travel control spool (located
on the bottom of control valve as shown in Fig.3),
to reduce or to increase the spool stroke
decreasing or increasing the oil flow to the travel
motor and therefore the speed revolution of drive
shaft.

Fig. 3
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PT10-5-13

COMPONENTS PERFORMANCE TEST EX135W

Second speed measurement - STANDARD

version:

(1) Set the controls as follows:

- Engine speed to maximum
- Set fast speed position (hare)
- Select second speed gear
- Operate the travel pilot valve (pedal) to forward
stroke-end.
(2) Stabilize the travel pressure from 190 to 200 bar
with the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
Measure the drive shaft revolution speed using
an electronic digital tachometer.

WARNING

Pay the utmost care to the wheel and drive shaft

revolutions in order to avoid injury to the people.

In case of the drive shaft revolution speed is out of

specification values, proceed as follows:

■ Operate on the adjusting screw of the travel

motor minimum displacement (Fig.4), screwing
to increase or loosen to decrease in order to
restore the drive shaft revolution speed within
the foreseen limit.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

Fig. 4
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PT10-5-14

COMPONENTS PERFORMANCE TEST EX135W

5.5 HYDRAULIC PUMPS

5.5.1 MAIN PUMP FLOW TEST

Measure the pressure and flow of the main pump, by

installing a flowmeter, complete with test hoses and
turbine, between the hydraulic supply flexible hoses of
arm cylinder.

Preparation:

(1) Set the front attachment to ground, completely

extended, then stop the engine and actuate
repeatedly the pilot valves in order to allow the oil
pressure to release.

Be sure that hydraulic oil should not

pressurized and overheated. F9328

(2) Bleed the air pressure from hydraulic tank,

unscrewing the bleed cap,
(3) Connect a vacuum pump to the oil tank supply Fig. 1
port.
(4) Actuate the vacuum pump, then disconnect the
flexible hoses (A and B) from arm cylinder.
(5) Install a flowmeter (C) complete of test hoses and
turbine (D), (Kit n.75298406) by means of two
M36x2 - 1"gas adapters in according to the Fig. 2.
(6) Disconnect the vacuum pump, then close the bleed
cap.
(7) Connect the engine tachometer sensor on fuel
injection feed pipe (Fig.1), after accurately cleaning
of contact zone, in order to verify the engine speed
during all the check procedure.
(8) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

Attention: Before starting the engine, make

sure that the flowmeter loading valve (E) should
be fully open.

(1) Start the engine and check for oil leakages from
the connections.
(2) Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
(3) Select the following switch position:

Auto idle switch

OFF
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(4) Verify, by means of the tachometer, that the engine

speed should be 2100 ± 50 rpm.
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PT10-5-15

COMPONENTS PERFORMANCE TEST EX135W

(5) Actuated the left hand pilot valve to full stroke

end in order to control the arm retraction.

(6) Slowly shut the followmeter loading valve (E) to

set the pressure to 200 bar (read on port M of
main pump).

(7) Read the pump flow indication on the flowmeter

and the pressure on related gauge.

Notes: • The pressure read on the pressure gauge

of the flowmeter correspond to the pump
pressure minus the ∆P pressure.

• In these conditions it is not possible to

check the pump maximum flow, but that
related to the user maximum flow.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

(Main Pump P - Q diagram)

B
A

C
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D
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E
Fig. 2
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PT10-5-16

COMPONENTS PERFORMANCE TEST EX135W

If the foreseen values in the P - Q curve can not be met, this does not mean a failure of the pump, but could
be caused by a setting change of the pump controller.
In order to make sure of the pump efficiency, the measurement of the oil quantity that drains from pump
housing (drain port T1 of main pump), can be required.
For your information, the maximum values used for new pumps releasing are quoted below.

Maximum acceptable limit of standard drain for new pumps

Pump pressure Oil quantity (*) Q max (l/min)

P (bar)

100 5.5

200 10.9

300 16.4

(*) with oil viscosity: 18 mm2/s

For the in service pumps, if the drain value is greater than three times the standard values quoted above, the
pump replacemend is recommended.( i.e.: Qmax= 16.4 l/min at 300 bar; replace with Q= 49.2 l/min).

Note: An excessive drain can determine an increasing pressure in the inside of the pump housing, that in
any way, must not exceed the 2 bar (absolute).

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PT10-5-17

COMPONENTS PERFORMANCE TEST EX135W

5.5.2 SECONDARY PUMP FLOW TEST

Measure the pressure and flow of the secondary

pump, by installing a flowmeter, complete with test
hoses and turbine, on the supply hose between
secondary pump and control valve.

Preparation:

(1) Bleed the air pressure from hydraulic tank,

unscrewing the bleed cap,
(2) Connect a vacuum pump to the oil tank supply
port.
(3) Actuate the vacuum pump, then disconnect the
supply hose (A) from control valve and connect
to the input of turbine (B) (short side).
(4) Install a flowmeter (C) complete of test hoses
F9328
and turbine (D), (Kit n.75298406) in according
to the
Fig. 2. Fig. 1
(5) Disconnect the vacuum pump, then close the
bleed cap.
(6) Connect the engine tachometer sensor on fuel
injection feed pipe (Fig.1), after accurately
cleaning of contact zone, in order to verify the
engine speed during all the check procedure.
(7) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

Attention: Before starting the engine, make

sure that the flowmeter loading valve (E) should D
be fully open. C

(1) Start the engine and check for oil leakages from
the connections.
(2) Maintain the hydraulic oil temperature at 50 ±
5°C (122 ± 9°F).
(3) Select the following switch position:

Auto idle switch A

B
OFF E

(4) Verify, by means of the tachometer, that the

engine speed should be 2100 ± 50 rpm.
(5) Slowly shut the followmeter loading valve (E) to
the pressure of 150 and 200 bar.
F4090
(6) Read the pump flow indication on the flowmeter Fig. 2
and the pressure on related gauge.
60406991

Evaluation:
21599

Refer to Group 2 - PERFORMANCE STANDARD.

(Secondary Pump P - Q diagram)
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PT10-5-18

COMPONENTS PERFORMANCE TEST EX135W

If the foreseen values in the P - Q curve can not be met, this does not mean a failure of the pump, but could
be caused by a setting change of the pump controller.
In order to make sure of the pump efficiency, the measurement of the oil quantity that drains from pump
housing (drain port L of secondary pump), can be required.
For your information, the maximum value used for new pumps releasing is quoted below.

Maximum acceptable limit of standard drain for new pumps

Pump pressure Oil quantity (*) Q max (l/min)

P (bar)

270 6.8

(*) with oil viscosity: 18 mm2/s

For the in service pumps, if the drain value is greater than three times the standard values quoted above, the
pump replacemend is recommended.

Note: An excessive drain can determine an increasing pressure in the inside of the pump housing, that in
any way, must not exceed the 2 bar (absolute).

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INDEX EX135W - 11 - 1

?
SECTION 11 APPENDIX

INDEX

Group 11 - APPENDIX ............................................................................................. APP11-1-1

11.1 Assembly and hdyraulic diagram of service solenoid valve group

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APP11-1-1

APPENDIX EX135W
11. APPENDIX

11.1 ASSEMBLY AND HYDRAULIC DIAGRAM OF SERVICE SOLENOID VALVE GROUP

- Solenoid valve A0 parking brake Two-way and two-position solenoid valve,

up to EX135W 77WM0071 (Monoboom) normally opened. It feeds pedal for travel
frame EX135WT 77WM0077 (Triple Arm) control or positioner arm depending on rest or
energizing condition of solenoid valves B3
and B4. This solenoid valve is energized by
parking brake button and in these conditions
it intercepts the possible travel control.

3
3 3
3 3
3
2

2
T
P1 T1
A1 A3 A4 A5 A6

A2
P

4
1

A0
A1 A2 A3 A4 A5 A6

1 - Body of service solenoid valve group

2 - Pilot control overpressure valve
3 - Three-way solenoid valves A1 - A2 - A3 - A4 - A5 - A6
4 - Two-way solenoid valve A A0
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3 3 3 3 3 3

F7014
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APP11-1-2

APPENDIX EX135W
11.1.1 PARKING BRAKE CONTROL LINE UP TO FRAME EX135W 77WM0071 (MONOBOOM)
EX135WT 77WT0077 (TRIPLE ARTICULATION ARM)

PARTS INVOLVED:

Solenoid valve A0 - A4
Fuse 28 - 31
Pressure switch P7
Relay R5 - R28
Switch SW1
Lamp L2
APC 50

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APP11-1-3

APPENDIX EX135W

NOTES:
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APP11-1-4

APPENDIX EX135W

ELECTRICAL SYSTEM DESCRIPTION UP TO FRAME EX135W WM77071 (MONOBOOM)

EX135WT WT77077 (TRIPLE ARTICULATION ARM)
1. Batteries 40. High engine coolant temperature sensor
2. Battery isolator relay 41. Hydraulic oil level sensor
3. Stater motor 42. Engine coolant level sensor
4. Starter relay 43. Engine oil level sensor
5. Fuse 4 (BOX B) 40 A 44. Fuel level sensor
6. Key-start switch 45. Engine coolant temperature sender
7. Diode 1 46. Low engine oil pressure sensor
8. Diode 6 47. Relay R13
9. Diode 2 48. Relay R14
10. Electrical stop 49. Relay R15
11. Horn button 50. Relay R22
12. Horn relay R7 51. Diagnostic tool connection (Dr. EX)
13. Windscreen washer electrical pump relay 52. Engine speed hand control
14. Horn 53. (SMC) main controller unit
15. Fuse 1 (BOX A) 40 Amp 54. E button (Economy mode)
16. EC motor 55. Relay R23
17. Left-hand control lever 56. Engine speed control unit
18. Alternator relay R1 57. Anti-load dump relay R3
19. Right-hand control lever 58. Safety relay R2
20. Windscreen wiper 59. Relay R27
21. Windscreen washer electrical pump 60. Electrical fuel lift pump
22. Cab light 61. Engine speed control unit panel light
23. Fuse box 62. Optional equipment connector
24. Relay R21 (opt) 63. Engine speed pedal enabling connector
25. Radio 64. Air conditioner pressure switch
26. Cigar lighter 65. Hour-counter
27. Diode 8 66. Engine coolant temperature gauge
28. Boom light (opt) 67. Fuel level gauge
29. Boom light 68. Instrument panel lighting
30. Blade relay R18 69. Engine oil level warning light
31. Boom light relay R6 70. Engine coolant level warning light
32. Alternator 71. Hydraulic oil level warning light
33. Diode 6 72. Battery charge malfunction warning light
34. Fuse 3 (BOX B) 80 A 73. Low engine oil pressure warning light
35. Electrical fan and control 74. High engine coolant temperature warning light
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36. Engine stop coil relay R17 75. Buzzer

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37. Diode 5 76. Blade solenoid valve

38. Diode 7 77. Air filter restriction warning light
39. Air filter restriction sensor
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APP11-1-5

APPENDIX EX135W

78. Low fuel level warning light 118. Relay R28

79. Windscreen wiper safety switch 119. Synchro-start relay
80. Angle (EC) sensor 120. Relay R11
81. Auto/idle engaged light (led) 121. Diode 4
82. E mode engaged light (led) 122. Relay R20
83. Stabilizer solenoid valve 123. Heated filter warning light (opt)
84. Programming switch connector 124.Relay R19
85. Level check button (CHECK) 125. Fuse 2 (BOX A) 40A
86. Buzzer stop button 126. Relay R8
87. Windscreen washer control button 127. TBG horn (opt)
88. Windscreen wiper control button 128. Relay R24
89. Work lights control button 129. TBG pressure switch (opt)
90. Blade/stabilizer solenoid valve 130. Cab lights (opt)
91. Blade/stabilizer solenoid valve 131. Relay R26
92. Solenoid valve for left bucket swing 132. Engine stop solenoid timer
93. Solenoid valve for right bucket swing 133. Relay R25
94. Hammer solenoid valve 134. Relay R4
95. Grass-cutter solenoid valve 135. Steering column
96. Crusher solenoid valve + TB 136. High pressure brake pressure switch
97. Crusher solenoid valve + TB 137. Stop light brake pressure switch
98. Controller Box 138. Work brake solenoid valve
99. Air conditioner control panel (opt) 139. Front lights
100. Air conditioning system (opt) 140. Front direction indicators
101. Auto/idle control button 141. Rear lights
102. Gear governor APC50 142. Number plate light
103. Relay R10 143. Loud-speakers
104. Solenoid valve C2 144. Aerial
105. Brale solenoid valve 145. Windscreen wiper C
106. First and second speed solenoid valve 146. Windscreen wiper B
107. Clutch disconnection solenoid valve 147. Windscreen wiper B
108. Travel speed sensor 148. Windscreen wiper B-M
109. Synchronization pressure gauge 149. Complete control module
110. Kick-down switch 150. Travel speed selector
111. Unused warning light 151. Automatic windscreen wiper connector
112. Pressure switch 152. Connector (normally open) (opt)
113. Relay R9 153. Rotating beacon
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114.Air conditioning compressor engage control (opt) 154. Travel pedal control check solenoid valve
21599

115. Relay R5 155. Equipment control check solenoid valve

116. Relay R16 156. Axle lock solenoid valve
117. Accumulator charge sensor
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APP11-1-6

APPENDIX EX135W

NOTES:

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APP11-1-9

APPENDIX EX135W

HYDRAULIC SYSTEM PARTS UP TO FRAME EX135W WM77071 (MONOBOOM)

EX135WT WT77077 (TRIPLE ARTICULATION ARM)

1. Diesel engine (optional)

2. Main pump and swing unit 37. Travel motor
3. Brakes pump and power steering unit 38. Slewing motor
4. Oil reservoir 39. Bucket cylinder
5. Return oil filter 40. Digging cylinder
6. Radiator 41. Lifting cylinders
7. Valve 42. Articulation cylinder
8. Solenoid valve for clamshell bucket swing 43. Hammer valve
9. Hydraulic steering unit (optional)
10. Delivery oil filter 44. Priority valve for controls feeding
11. Pressure switch for insufficient brake charge 45. Swing brake
pressure 46. Gearbox accumulator
12. Accumulator, servo-controls 47. Inlet block and discharges
13. One-way throttling valves 48. Antidrop valve
14. Parking brake (optional)
15. Transmission control valve 49. Grass-cutter
16. One-lever joystick (optional)
17. Foot control 50. Hammer
18. Braking system accumulators (optional)

19. Transmission 51. Clamshell bucket

(optional)
20. Control valve
52. Selection valve
21. Solenoid valve
(optional)
22. Stop lights pressure switch
53. Valve
23. Service solenoid valves
54. Pressure intakes
24. Braking system valve
55. Crusher
25. Slewing valve
(optional)
26. Travel valve
56. Crusher valve
27. Selection valve for dozing blade/stabilizers
(optional)
(optional)
28. Axle lock-out valve
29. Solenoid valve for travel engine braking
30. Front steering steering
31. Front axle with brake
32. Rear axle with brake and gearbox
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33. Lock-out valve

(optional)
21599

34. Axle lock-out cylinders

35. Cocks
36. Cylinders for dozing blade and/or stabilizers
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APP11-1-10

APPENDIX EX135W

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